Importance of Laminated Tubes in Packaging

Laminated tubes have quietly become one of the most important packaging formats on the planet. From the toothpaste tube in your bathroom to the antifungal cream in your medicine cabinet, the laminated tube is the industry-standard packaging for semi-solid and paste products across pharmaceuticals, cosmetics, oral care, and food. This guide explains why — and what makes laminated tube packaging the preferred choice for global brands and regulated markets alike.

The global laminated tubes market was valued at USD 3.47 billion in 2025 and is projected to reach USD 5.09 billion by 2035, growing at a CAGR of 3.9%. Laminated tubes already hold a 46%+ market share of all tube packaging globally — a clear signal of their dominance across consumer and regulated industries.

A laminated tube is a multilayer squeeze tube constructed by bonding together several functional layers of material. Unlike a simple plastic or aluminium tube, each layer in a laminated tube serves a distinct purpose:

 

Layer	Function
Outer polyethylene (PE)	Print surface — accepts high-resolution flexographic / digital printing
Tie layer	Bonds the outer PE to the barrier layer securely
Aluminium foil (ABL) or EVOH / PA (PBL)	Core barrier — blocks moisture, oxygen, UV, and aroma migration
Tie layer	Bonds the barrier to the inner contact layer
Inner polyethylene (PE)	Direct drug/product contact — chemically inert, FDA-compliant virgin LDPE

 

The standard laminate structure is approximately 275 microns total thickness, and tubes are manufactured in diameters ranging from ½" to 2" (13.5 mm to 50 mm), with a wide variety of shoulder profiles, neck diameters, and cap/closure options to suit each product category.

ABL (Aluminium Barrier Laminate) uses a thin aluminium foil as the barrier — giving it near-total impermeability to moisture, oxygen, and light. PBL (Plastic Barrier Laminate) uses a plastic barrier (EVOH or polyamide) instead, making it lighter, more recyclable, and more squeeze-friendly, at a marginally lower barrier performance level.

The importance of laminated tube packaging comes from an exceptional combination of functional, commercial, and regulatory properties that few other packaging formats can match. Here are the seven core reasons why industries from pharmaceuticals to food continue to choose laminated tubes:

1. Superior barrier protection extends shelf life

The multi-layer wall construction of a laminated tube creates an effective shield against moisture vapour, atmospheric oxygen, UV radiation, dust, and microbial contamination. This is the most critical reason pharmaceutical manufacturers rely on laminated tubes for creams, ointments, and gels: the formulation's active ingredients remain potent and stable from the fill date to the last dose dispensed. Laminated tubes can extend the shelf life of sensitive formulations by 12 to 24 months compared to single-layer plastic alternatives.

2. Cost-effective alternative to aluminium tubes

Laminated tubes combine the barrier performance of aluminium tubes with the lower cost and design flexibility of plastic. The lamination process enables high-volume production at competitive per-unit costs, making them the most cost-effective primary packaging option for semi-solid products at commercial scale. The oral care industry alone accounts for 65–70% of global laminated tube production, largely because of this price-performance advantage.

3. Excellent sealability and leak-proof performance

The flexible, smooth exterior of a laminated tube delivers excellent heat-seal performance at the tube's end, creating a fully leak-proof closure. Combined with the tight-fitting shoulder and cap assembly, this ensures zero product leakage during transport, storage, and use — a non-negotiable requirement for pharmaceutical and food applications. The tube also demonstrates a natural 'suck-back' tendency, reabsorbing small excess quantities dispensed at the nozzle, which reduces waste and keeps the cap and nozzle area clean.

4. High-quality printed branding and regulatory labelling

The smooth outer polyethylene surface accepts up to 8-colour flexographic and digital printing with exceptional resolution. This enables brands to simultaneously display: full-colour brand graphics; regulatory compliance information (ingredients, directions for use, allergy warnings, batch codes, expiry dates, barcodes); and anti-counterfeiting features — all on a single tube surface without any secondary labelling. This is especially important for pharmaceutical tube packaging, where regulatory authorities mandate specific information density on primary packaging.

5. Lightweight, durable and unbreakable

Laminated tubes are significantly lighter than rigid containers such as glass jars or aluminium bottles. This reduces shipping costs across the supply chain and improves patient convenience — particularly important for elderly patients or those managing topical treatments long-term. Unlike glass or rigid plastic, laminated tubes are unbreakable and resistant to cracking under normal handling conditions, dramatically reducing product loss from packaging failure.

6. Customisable to exact product and brand requirements

Unlike most rigid packaging formats, laminated tubes are an inherently customisable product. Every dimension — diameter, length, shoulder type, neck size, cap type — can be specified to match the product's viscosity, dispensing requirements, and consumer usage behaviour. Custom printed laminated tubes can be produced in runs as small as 1,000 units for niche brands, or in multi-million unit volumes for global CPG companies, using the same production infrastructure.

7. Compatible with diverse product chemistries

The inner polyethylene layer is chemically inert and non-reactive with a wide range of pharmaceutical, cosmetic, and food formulations — including those with high water activity, low pH, or active pharmaceutical ingredients. The tube material does not leach into the contents and does not catalyse degradation of sensitive actives, meeting the 'non-toxic, non-reactive' standard required for all primary pharmaceutical packaging.

 

KEY INSIGHT Laminated tubes are the only packaging format that simultaneously delivers aluminium-level barrier performance, plastic-level manufacturing economics, and full-surface print quality — in a single, lightweight, squeeze-dispensing package. This is why they hold over 46% of the global tube packaging market.

Laminated tubes serve as the primary packaging format across five major global industries. Each benefits from different aspects of the laminated tube's technical properties:

Oral care — 65–70% of global production

The oral care sector — toothpaste, teeth-whitening gels, mouthwash gels, fluoride treatments — is the single largest user of laminated tubes worldwide. ABL tubes specifically are the format of choice for prescription and sensitivity toothpastes because of their near-total oxygen and moisture barrier. Explore our oral care tube packaging options.

Pharmaceuticals & healthcare

Laminated tubes are used extensively for topical medicated creams and ointments, antifungal preparations, corticosteroid creams, oral gels, eye ointments, and muscle relaxant gels. Pharmaceutical laminated tubes must comply with USFDA regulations (21 CFR 175.300), be DMF-registered, and be manufactured under cGMP. Our tubes meet all these requirements.

Cosmetics & personal care

The cosmetics industry accounts for a significant share of laminated tube consumption — face creams, serums, body lotions, hair dyes, shaving creams, and sunscreen products are all commonly packaged in cosmetic laminated tubes. The high-resolution printing capability makes laminated tubes particularly attractive for prestige and premium beauty brands where shelf impact is a competitive differentiator. The cosmetic laminated tube packaging market was valued at USD 1.35 billion in 2024 and is expected to reach USD 2.1 billion by 2032 (CAGR 6.5%).

Food packaging

In the food sector, laminated tubes package products including condiments, mustard, mayonnaise, tomato paste, cheese spreads, and confectionery pastes. The food packaging tube format ensures hygienic, portion-controlled dispensing while the aluminium barrier maintains freshness and prevents flavour or aroma migration — critical for high-quality food products.

Industrial & specialty

Laminated tubes are also used in industrial applications including adhesives, sealants, lubricants, shoe polish, crayons, and artist paint tubes. The consistent dispensing and chemical resistance properties of laminated tubes make them suitable for high-viscosity industrial formulations.

 

Industry	Typical Products	Preferred Tube Type
Oral care	Toothpaste, whitening gels, fluoride treatments	ABL (aluminium barrier)
Pharmaceuticals	Creams, ointments, oral & eye gels	ABL or PBL (FDA-grade)
Cosmetics	Face creams, serums, sunscreen, hair dye	ABL or PBL
Food	Condiments, pastes, cheese spreads	ABL (food-grade)
Industrial	Adhesives, shoe polish, crayons, lubricants	PBL (cost-optimised)

The barrier system of a laminated tube is its most critical engineering feature. Each layer contributes a specific protective function:

 

Barrier Property	What It Prevents
Moisture vapour barrier (WVTR)	Water ingress that hydrates / degrades formulations
Oxygen barrier (OTR)	Oxidation of active ingredients and colour change
UV / light barrier	Photodegradation of photosensitive actives
Aroma / fragrance retention	Volatile ingredient loss; cross-contamination of scent
Chemical resistance	Reaction between formulation acids/alkalis and packaging
Microbial barrier	Contamination of sterile or preservative-free formulations

 

ABL tubes deliver a high-gloss outer surface, fragrance protection with reduced aroma absorption, and a maximum chemical compatibility barrier — the three protective properties most frequently cited by formulators when specifying primary packaging for premium products.

Sustainability has become a central purchasing criterion for global CPG brands, and laminated tube packaging is actively evolving to meet these requirements. Here is where the industry currently stands:

PBL tubes: the more sustainable choice

PBL (Plastic Barrier Laminate) tubes, which use EVOH rather than aluminium as the barrier layer, are easier to recycle in many municipal streams because they are effectively monomaterial polyethylene. They are lighter in weight, use fewer raw materials, and generate a lower carbon footprint during production. Major brands including Colgate-Palmolive have deployed recyclable laminated tubes globally in partnership with manufacturers such as EPL Limited.

PCR content and bio-based materials

Leading manufacturers including Montebello Packaging (our parent supplier) and Albéa now offer laminated tubes with post-consumer recycled (PCR) polyethylene content, reducing reliance on virgin fossil-fuel-based plastic. Albéa's Greenleaf™ recycle-ready laminate tube — certified by APR and RecyClass — is expected to comprise 70% of North American tube production by 2025. Bio-based PE from sugarcane-derived ethanol is also entering the market as a premium sustainable option.

ABL tubes and the recycling challenge

ABL tubes present a greater recycling challenge because the aluminium foil layer is difficult to separate from the polyethylene in standard recycling streams. However, specialist recycling programmes exist, and the total lifecycle carbon footprint of ABL tubes can still compare favourably to glass or rigid plastic alternatives when extended shelf life (reduced food waste) and lightweight transport savings are factored in.

SUSTAINABILITY COMMITMENT Pharmaceutical Tubes / Adsorbtek Solutions offers both ABL and PBL laminated tube options, including PCR-content variants from Montebello Packaging — Canada's leading FDA-approved tube manufacturer. Ask our team about eco-friendly alternatives for your product.

Selecting the optimal laminated tube requires matching the tube's technical specification to the product's formulation requirements, regulatory environment, and commercial needs. Use this decision framework:

 

Selection Factor	What to Consider
Formulation sensitivity	Highly sensitive / photosensitive actives → ABL; standard formulations → PBL
Regulatory market	US FDA, EU, Health Canada → verify DMF, 21 CFR 175.300, ISO 15378
Product viscosity	Higher viscosity (e.g., heavy ointments) → larger diameter, wider nozzle
Tube capacity	Match fill weight: ranges from 3 ml (sample) to 250+ ml (clinical bulk)
Dispensing control	Precise dosing required → nozzle cap; easy-use → flip-top cap
Sustainability target	PCR or PBL options for brands with ESG commitments
Branding requirements	Premium shelf appeal → ABL with high-gloss print; budget → standard PBL
Child safety	OTC medicines for children → child-resistant closure variant

 

1. Define your formulation's sensitivity class (light, oxygen, moisture requirements).
2. Confirm the regulatory markets you are targeting and required certifications.
3. Specify capacity, diameter, and dispensing cap type based on usage behaviour.
4. Select ABL or PBL based on barrier requirements and sustainability policy.
5. Request validated barrier performance data (WVTR, OTR) from your supplier.
6. Run ICH Q1A stability testing with final tube samples before production commitment.

 

Q  Why are laminated tubes preferred over aluminium tubes for most products?

Laminated tubes offer nearly identical barrier performance to aluminium tubes (especially ABL types), but at lower cost, with better printability, and with the flexible, squeezable feel that consumers prefer. Aluminium tubes hold their shape after squeezing, which can look unappealing and suggest the product is running out. Laminated tubes spring back smoothly. For most cosmetic, oral care, and over-the-counter pharma products, laminated tubes are the optimal balance of protection, presentation, and economics.

Q  What is the shelf life of products packaged in laminated tubes?

Properly filled and sealed laminated tubes can extend product shelf life by 12 to 24 months compared to single-layer plastic alternatives. ABL tubes with full aluminium barrier can maintain product stability for 3 to 5 years in appropriate storage conditions — making them suitable for pharmaceutical products that require extended shelf life declarations on regulatory submissions.

Q  Are laminated tubes FDA approved for pharmaceutical use?

Yes. High-quality laminated pharmaceutical tubes are manufactured in compliance with USFDA 21 CFR 175.300 and are DMF (Drug Master File) registered. Our tubes, supplied by Montebello Packaging (Canada), hold an active DMF with the USFDA and comply with current Good Manufacturing Practices (cGMP). EU-compliant versions meeting ISO 15378 are also available.

Q  Can laminated tubes be recycled?

PBL (Plastic Barrier Laminate) tubes are largely recyclable in standard polyethylene streams. ABL tubes require specialist recycling due to the aluminium layer. Sustainable options including PCR-content tubes and mono-material recyclable constructions are available from our supplier Montebello Packaging, including APR/RecyClass-certified variants.

Q  What is the minimum order quantity for custom printed laminated tubes?

Minimum order quantities vary by manufacturer and tube specification, but custom printed laminated tubes are typically available from 1,000 units for standard sizes. For highly customised tube specifications (unusual diameters, special caps, specialist barrier structures), minimum orders are typically 5,000 to 25,000 units. Contact our team for a tailored quote.

Q  What is the difference between ABL and PBL laminated tubes?

ABL (Aluminium Barrier Laminate) tubes contain a thin aluminium foil layer as the core barrier — providing near-total impermeability to moisture, oxygen, UV light, and aroma. They are ideal for highly sensitive pharmaceutical and premium cosmetic formulations. PBL (Plastic Barrier Laminate) tubes use an EVOH or polyamide barrier instead — making them lighter, more recyclable, and slightly lower in cost, but with marginally lower barrier properties. PBL is preferred for less sensitive formulations and sustainability-focused brands.

Q  How do I get a quote for laminated tubes?

Contact the Pharmaceutical Tubes team (Adsorbtek Solutions) with your product specifications: tube diameter, length, fill weight, cap type, print design brief, required certifications, and target annual volume. We will provide a detailed quotation within 48 hours. Visit pharmaceuticaltubes.com/contact or email info@adsorbteksolutions.com.