Not all tubes are made the same. The material your tube is made from affects everything from barrier performance and sustainability to feel, appearance, and cost. If you are sourcing tube packaging for the first time or looking to switch materials, this guide breaks down the four main tube material categories and what makes each one unique.
Extruded Plastic Tubes
Extruded tubes are made by pushing molten plastic through a die to create a seamless tube body. They are the most common type of tube packaging and are used across cosmetics, personal care, hair care, and food industries. The entire tube is made from a single plastic material, typically LDPE (Low Density Polyethylene) or HDPE (High Density Polyethylene).
Extruded tubes are lightweight, flexible, and cost effective. They are a great all-around choice for products that do not require high barrier protection. They are also highly compatible with a wide range of decoration methods including silk screen printing, offset printing, and hot stamping.
Top Tubes offers both single layer and multi-layer extruded tubes, including 5-layer coextrusion options. Multi-layer coextruded tubes allow you to combine different plastic materials in a single tube wall, giving you improved barrier performance, better squeeze and recovery, or enhanced structural properties without switching to a laminate tube.
Best for
- Cosmetics, hair care, and personal care products
- Products with low to moderate barrier requirements
- Brands looking for a cost effective tube option
- High volume production runs
Laminate Tubes
Laminate tubes are constructed from multiple layers of different materials bonded together. The layered structure allows manufacturers to engineer specific barrier properties into the tube wall. There are two main types of laminate tubes: ABL and PBL.
ABL (Aluminum Barrier Laminate) tubes have an aluminum foil core that provides excellent protection against oxygen, light, and moisture. They are widely used for oral hygiene products, sensitive skincare formulas, and any product that requires maximum barrier performance.
PBL (Plastic Barrier Laminate) tubes use an EVOH plastic barrier layer instead of aluminum. They offer good barrier protection while being fully recyclable, making them a popular choice for brands with sustainability goals.
Best for
- Products requiring strong barrier protection
- Oral hygiene and sensitive formulas
- Brands prioritizing recyclability with PBL
- Premium decoration and print quality
PCR Tubes (Post-Consumer Recycled Plastic)
PCR tubes are made using plastic that has already been collected, processed, and recycled from consumer waste streams. By incorporating PCR content into your tube, you are reducing demand for virgin plastic and giving existing materials a second life.
PCR tubes are available in varying percentages of recycled content. A tube might be made from 25%, 50%, or up to 100% post-consumer recycled plastic. The appearance and performance of PCR tubes is very similar to standard extruded tubes, though color options may be slightly more limited due to the nature of recycled materials.
PCR is one of the most popular sustainable packaging choices right now because it directly addresses plastic waste without requiring new infrastructure or consumer behavior changes.
Best for
- Brands with sustainability commitments
- Products targeting eco-conscious consumers
- Brands looking to reduce virgin plastic use
- Cosmetics, personal care, and hair care
Bio-PE Tubes (Sugarcane-Derived Polyethylene)
Bio-PE tubes are made from polyethylene derived from sugarcane ethanol rather than fossil fuels. The sugarcane plant absorbs CO2 as it grows, which gives Bio-PE a significantly lower carbon footprint compared to conventional petroleum-based plastic.
From a performance standpoint, Bio-PE tubes look, feel, and perform exactly like standard LDPE tubes. They are flexible, lightweight, and compatible with the same decoration methods. They are also recyclable through standard plastic recycling streams, making them a strong all-around sustainable choice.
Bio-PE is particularly popular with premium beauty and personal care brands that want to communicate a clear sustainability story to their customers.
Best for
- Brands prioritizing carbon footprint reduction
- Premium beauty and personal care products
- Brands wanting a drop-in replacement for standard LDPE
- Products targeting sustainability-driven consumers
Choosing the Right Material for Your Product
The right tube material depends on your product formula, your sustainability goals, your target market, and your budget. Here is a simple way to think about it. If barrier protection is your top priority, choose ABL laminate. If recyclability matters most, choose PBL or Bio-PE. If reducing virgin plastic use is your goal, choose PCR. If you need a reliable, cost effective all-rounder, extruded plastic is your best bet.
Still not sure which material is right for your product? The team at Top Tubes is happy to help you evaluate your options and find the best fit for your formula and brand.
About Top Tubes
Top Tubes is a USA-based B2B supplier of custom ABL, PBL, and extruded plastic tube packaging serving the cosmetics, personal care, hair care, pharmaceutical, oral hygiene, and food industries. We offer low minimum order quantities, fast lead times, and a full range of decoration options. Contact us today to request samples or a quote.