Plastic Collapsible Tube Manufacturing: ABL vs PBL — A Complete Equipment Guide

Plastic collapsible tubes are one of the most versatile and cost-effective packaging formats for pharmaceuticals, cosmetics, food, and industrial products. From hand creams to topical ointments, the humble squeeze tube delivers precise dosing, excellent barrier properties, and strong consumer appeal.

If you are evaluating plastic tube production equipment, this guide covers the key technical decisions — ABL vs PBL tubes, materials, printing, and how to size a production line for your market.

What Are Collapsible Plastic Tubes?

A collapsible tube is a seamless, one-piece container made from laminated or extrusion plastic, designed to collapse progressively as the contents are dispensed. The crimped shoulder is sealed to a cap, creating a tamper-evident, hermetic package.

Key advantages over rigid containers: dose control, no-drip dispensing, lightweight, and low material cost.

ABL vs PBL Tubes: What's the Difference?

The core distinction is how the tube body is formed:

Extrusion Blow Molding (EBL) Tubes

In extrusion blow molding, plastic pellets are melted and extruded as a hollow tubeparison profile, which is then inflated within a mold cavity to take the tube shape. This is the most common method for pharmaceutical-grade plastic tubes.

Characteristics:

• Consistent wall thickness
• Cost-effective for high volumes
• Limited decoration options (primarily offset or flexo printing)
• Typically used for short-to-medium barrier applications

Laminated Tubes (ABL)

ABL tubes are made by laminating multiple material layers (typically aluminum barrier + plastic) into a sheet, which is then formed into a tube and sealed at the tail. The aluminum barrier provides superior gas and moisture protection.

Characteristics:

• Excellent oxygen and moisture barrier (critical for sensitive formulations)
• High-quality offset printing surface
• Typically used for pharmaceuticals, premium cosmetics
• Slightly higher cost per unit than extrusion tubes

Polyethylene Barrier (PBL) Tubes

PBL tubes replace the aluminum barrier with a co-extruded polyethylene-EVOH barrier layer. No aluminum means the tube is fully squeezable, radiation sterilizable, and suitable for sensitive biologics.

Characteristics:

• Excellent barrier with full squeezability
• Radiation/gamma sterilizable (unlike aluminum-lined tubes)
• Ideal for pharmaceutical and medical applications
• Suitable for sensitive APIs and biologics

Material Selection Guide

Material	Properties	Typical Application
LDPE (Low Density PE)	Soft, squeezable, chemical resistant	Cosmetics, lotions, gels
HDPE (High Density PE)	Rigid, good barrier, stands upright	Pharmaceutical ointments, creams
Polypropylene (PP)	High temp resistance, clear option	Sterile pharmaceuticals
EVOH Barrier	Oxygen barrier (0.5 mm EVOH = 60+ Al)	ABL and PBL tubes

Tube Specifications and Dimensions

Tube dimensions are standardized but customizable:

• Diameter: 13mm to 60mm (most common: 19mm, 22mm, 25mm, 28mm, 35mm)
• Length: 50mm to 200mm
• Wall thickness: 0.4mm to 0.9mm
• Cap types: Screw cap, flip-top, pipette, nozzle
• Shoulder types: Standard, long-cap, nasal tip

How a Tube Making Line Works

YohoAI's tube production lines combine multiple process stages in an integrated system:

Step 1: Extrusion / Lamination

Plastic resin (or laminated sheet) is fed into the tube extrusion head, forming a continuous tubeparison at the precise diameter and wall thickness.

Step 2: Tube Forming

The hot tube is pulled through cooling jaws and a forming die that shapes the shoulder and thread for cap application. Precision controls ensure consistent shoulder geometry for proper cap fit.

Step 3: Crimping / Tail Sealing

For ABL tubes, the tail is sealed using heat welding. For PBL/extrusion tubes, the tube is cut to length and the tail is folded and crimped.

Step 4: Printing (Inline or Offline)

High-speed tube lines include inline flexographic or offset printing units for branding, product information, and regulatory text. Some lines feed pre-printed laminated sheets.

Step 5: Capping and Coding

Caps are fed from a bowl feeder, applied to the shoulder with controlled torque, and batch coding (expiry, lot number) is applied via inkjet or laser coder.

Step 6: Quality Inspection

Visual inspection cameras, seal integrity testers, and weight checkers ensure every tube meets specification before packing.

Production Speed and Capacity

Machine Type	Speed	Typical Output
Semi-automatic tube line	20–40 tubes/min	Small batch / lab
YG-60 series (standard)	60–80 tubes/min	Medium production
YG-100 series (high-speed)	100–150 tubes/min	High-volume commercial

Regulatory Considerations for Pharmaceutical Tubes

• Tubes for pharmaceutical use must comply with USP <661> (Plastic Packaging Systems) and EP 3.1.3 (Polyethylene)
• Extractables and leachable testing is required for new formulations
• DMF Type IV or equivalent documentation must be provided by the tube manufacturer
• For sterile products: gamma or E-beam sterilization compatibility must be verified

Cost Comparison: ABL vs PBL vs Extrusion

Why Manufacture Tubes In-House?

Many pharmaceutical and cosmetics companies that once outsourced tube procurement are now bringing production in-house because:

• Cost control: 30–50% reduction in packaging cost per unit
• Supply chain resilience: No dependency on external converters with long lead times
• Customization speed: Faster response to regulatory label changes or seasonal SKUs
• Quality ownership: Full control over barrier properties, seal integrity, and print quality

Key Takeaways

• Choose ABL for maximum barrier and premium print quality in pharmaceuticals
• Choose PBL for radiation-sterilizable, fully squeezable pharmaceutical tubes
• Choose extrusion tubes for cost-sensitive, non-sterile cosmetic and food applications
• An in-house tube line pays back in 18–36 months versus outsourced procurement
• YohoAI supplies complete tube making lines with IQ/OQ documentation for global regulatory submissions