Choosing a tube is not only about its appearance. The tube structure can affect product protection, flexibility, shape recovery, decoration, sustainability positioning, and the overall consumer experience.
The three most common options are:
- ABL - Aluminum Barrier Laminate
- PBL - Plastic Barrier Laminate
- PE Co-Ex - Polyethylene Co-Extrusion
Each structure has different strengths. The right choice depends on what is inside the tube, the level of protection required, how the tube should feel, and how the brand wants to present the product.
Quick Comparison: ABL, PBL and PE Co-Ex
| Feature | ABL | PBL | PE Co-Ex |
|---|---|---|---|
| Main barrier | Aluminum foil | Plastic barrier such as EVOH or PET | Multi-layer PE structure, optionally with EVOH |
| Barrier performance | Very high | Good to high | Adjustable according to layer structure |
| Light protection | Excellent | Good to excellent, depending on structure | Depends on color and structure |
| Flexibility | Moderate | Good | Very good |
| Shape recovery | Lower | Better than ABL | Excellent |
| Tube-body seam | Visible side seam | Visible side seam | Seamless tube body |
| Surface appearance | Crisp and structured | Smooth and premium | Soft and natural |
| Typical applications | Oral care, pharmaceutical and sensitive formulations | Skincare, personal care and premium cosmetics | Skincare, personal care, pharmaceutical and specialty products |
| Key consideration | Maximum product protection | Balance of protection and appearance | Flexibility and comfortable dispensing |
This comparison is a starting point. Final material selection should be confirmed through compatibility and product testing.
1. ABL: Maximum Barrier Protection
ABL stands for Aluminum Barrier Laminate. Its structure incorporates a thin aluminum barrier layer between protective plastic and adhesive layers.
The aluminum layer provides strong protection against:
- Oxygen
- Moisture
- Light
- External contamination
- Aroma or active-ingredient loss
This makes ABL a strong option for products that are sensitive to environmental exposure or require dependable protection throughout their intended shelf life.
When should a brand choose ABL?
ABL is commonly selected for:
- Toothpaste and oral-care products
- Pharmaceutical ointments and gels
- Medicated creams
- Industrial adhesives and specialty products
- Formulations requiring high barrier protection
ABL also provides a firm, structured feel that is familiar in toothpaste and pharmaceutical packaging.
What should brands consider?
Because aluminum has lower shape recovery than plastic-based structures, an ABL tube may retain dents or folds after being squeezed. Its metallic barrier can also be visible at the tube’s side seam or exposed edges, depending on the tube design.
For products where maximum protection is more important than a soft, highly resilient tube, ABL is often the most suitable starting point.
2. PBL: Balanced Protection and Premium Appearance
PBL stands for Plastic Barrier Laminate. Instead of aluminum, it uses a plastic barrier layer (commonly EVOH or PET) within the laminate structure.
PBL combines reliable product protection with greater flexibility and a predominantly plastic appearance. This makes it especially attractive for skincare, beauty and personal-care products.
Why do brands choose PBL?
PBL offers:
- Good oxygen and moisture protection
- Better flexibility than ABL
- A smooth, consistent surface
- Good shape recovery
- Compatibility with high-quality printing and decoration
- A premium appearance suitable for beauty categories
Depending on the selected structure, PBL can be produced with white, transparent, metallized or other visual effects.
When should a brand choose PBL?
PBL is well suited for:
- Facial cleansers
- Skincare creams and treatments
- Body lotions and serums
- Sunscreen
- Hair-care products
- Personal-care gels
- Premium cosmetic products
PBL is often the preferred middle ground when a product requires more protection than a standard PE structure but the brand wants a softer, more cosmetic appearance than conventional ABL.
What should brands consider?
PBL provides strong barrier performance, but it may not always match the maximum protection offered by aluminum-based structures. The correct specification depends on the formulation, expected shelf life and distribution conditions.
3. PE Co-Ex: Soft, Flexible and Seamless
PE Co-Ex tubes are produced by co-extruding multiple material layers into a continuous tube body. Unlike laminate tubes, the body does not require a longitudinal side seam.
The structure can be engineered using different layer configurations, including 2-layer, 3-layer, 5-layer and more advanced 6-layer constructions. Depending on the product requirement, a barrier layer such as EVOH or a PCR-containing layer may also be incorporated.
Why do brands choose PE Co-Ex?
PE Co-Ex tubes offer:
- A soft and comfortable squeezing experience
- Strong shape recovery
- A seamless tube body
- Good resistance to repeated handling
- Flexible structural design
- A natural fit for skincare and personal care
- Options for different surface finishes and decoration
Because of their soft feel and resilience, Co-Ex tubes can create a more comfortable and premium dispensing experience.
When should a brand choose PE Co-Ex?
PE Co-Ex is commonly used for:
- Skincare products
- Facial cleansers
- Body and hand creams
- Personal-care products
- Pharmaceutical and topical products
- Specialty formulations
- Products positioned around convenience and comfortable use
What should brands consider?
Barrier performance varies according to the number of layers and the materials selected. A standard PE structure may not provide the same level of protection as ABL, while an engineered multi-layer structure with EVOH can provide enhanced barrier performance.
Co-Ex should therefore be specified based on the formulation rather than selected only for its softer feel.
Which Tube Structure Is Right for Your Product?
There is no single tube structure that is best for every application. A practical selection process should begin with the product itself.
Choose ABL when:
- Maximum barrier performance is the main priority
- The formulation is highly sensitive to oxygen, moisture or light
- The product is in oral care, pharmaceutical or industrial applications
- A firmer and more structured tube is acceptable
Choose PBL when:
- You need a balance between barrier protection and flexibility
- Premium appearance is important
- The product is positioned in skincare, cosmetics or personal care
- You want plastic-based aesthetics with laminate printing quality
Choose PE Co-Ex when:
- Softness and shape recovery are important
- You prefer a seamless tube body
- The consumer will use and squeeze the tube frequently
- The structure needs to be engineered for specific performance or PCR integration
Five Questions to Answer Before Selecting a Tube
Before deciding between ABL, PBL and Co-Ex, consider these questions:
- What formulation will be packed inside the tube?
- Is the product sensitive to oxygen, moisture, light or aroma loss?
- What shelf life and storage conditions are expected?
- What tube feel and dispensing experience should the consumer have?
- What printing, decoration, closure and sustainability requirements must be achieved?
The answers will help determine not only the tube structure, but also its thickness, diameter, length, barrier level, decoration and closure system.
Structure Is Only One Part of the Decision
A successful tube package requires every component to work together:
- Formula and material compatibility
- Tube structure and thickness
- Diameter and filling volume
- Shoulder and orifice design
- Closure selection
- Printing and decoration
- Filling and sealing conditions
- Transportation and storage requirements
This is why early packaging consultation is valuable. It reduces the risk of selecting a visually attractive tube that does not perform properly with the formulation or filling process.
Build the Right Tube with Lamipak
Lamipak provides ABL, PBL and PE Co-Ex tube solutions for oral care, skincare, personal care, pharmaceutical and specialty applications.
From structure selection and artwork preparation to tube manufacturing, decoration and commercial delivery, our team can help align the packaging with your product and market requirements.
Have a product in development? Discuss your formulation, application and packaging requirements with our team.