What is a 5-Layer Flexible Tube? A Game-Changer in Sunscreen Packaging

by | Mar 3, 2025 | Articles

sunscreen-packaging-tubes

What is a 5-Layer Flexible Tube? A Game-Changer in Sunscreen Packaging

Packaging plays a crucial role in protecting cosmetic and pharmaceutical products from external factors like oxygen, moisture, and UV radiation. 5-layer flexible tubes have emerged as a superior solution, offering enhanced barrier protection for products like sunscreen, toothpaste, and skincare formulations. But what exactly is a 5-layer flexible tube, and how does it compare to other types of packaging? Let’s explore.

What is a 5-Layer Flexible Tube?

A 5-layer flexible tube is a multi-layered packaging solution that combines different materials to create a highly protective barrier against oxygen, moisture, and UV exposure. It typically consists of:

  1. Outer Layer – Provides durability and branding possibilities (often made of LDPE or HDPE).
  2. Adhesive Layer – Ensures strong bonding between layers.
  3. Barrier Layer (EVOH or Aluminum Foil) – Prevents oxidation and preserves active ingredients.
  4. Adhesive Layer – Additional bonding for structural integrity.
  5. Inner Layer – The product-contact layer, ensuring compatibility with the formula.

This structure makes 5-layer tubes particularly effective for sunscreen packaging, where maintaining the stability of UV filters is crucial.

5-Layer Flexible Tube vs. Single-Layer and ABL Tubes: Key Differences

Feature Single-Layer Tube ABL Tube (Aluminum Barrier Laminate) 5-Layer Flexible Tube
Barrier Protection Low – allows oxygen and moisture penetration. High – aluminum layer provides strong barrier. High – EVOH layer prevents oxidation and extends shelf life.
Squeezability Very flexible and soft. Less flexible due to aluminum. Retains flexibility while offering better protection.
UV Resistance Limited – can cause product degradation. Moderate – aluminum blocks UV rays. Excellent – EVOH effectively blocks UV rays.
Eco-Friendliness Usually made of PE, recyclable but less durable. Harder to recycle due to aluminum layer. Some variations include PCR (Post-Consumer Recycled) materials for sustainability.
Application Basic creams and lotions. Toothpaste, pharmaceuticals. Sunscreen, premium skincare, and sensitive formulations.

Why These Differences Matter

For sunscreen packaging, barrier protection is critical. UV exposure and oxidation can degrade active ingredients, reducing the SPF effectiveness. 5-layer flexible tubes solve this issue by ensuring superior protection while maintaining the ease of use and premium feel.

Why 5-Layer Flexible Tubes are Ideal for Sunscreen Packaging

  1. Prevents Oxidation of Active Ingredients
    1. Sunscreens contain UV filters (e.g., avobenzone, oxybenzone) that are sensitive to oxygen and light. The EVOH barrier in 5-layer tubes helps prevent oxidation, preserving SPF stability.
  2. Enhances Product Shelf Life
    1. By blocking moisture and oxygen, these tubes extend the shelf life of sunscreen, reducing product waste and ensuring consistent performance over time.
  3. Combines Protection with Squeezability
    1. Unlike ABL tubes, which can be stiff, 5-layer tubes retain flexibility, making it easier for consumers to dispense the product smoothly.
  4. Eco-Friendly and Sustainable Options Available
    1. Some manufacturers offer PCR (Post-Consumer Recycled) versions, making them a more sustainable alternative to traditional laminated tubes.
  5. Premium Look and Feel for Branding
    1. The outer PE layer allows for high-quality printing, making 5-layer tubes visually appealing for premium sunscreen brands.

The Future of 5-Layer Flexible Tubes in Packaging

As sustainability becomes a top priority, 5-layer tubes are evolving to incorporate biodegradable materials, improved recyclability, and reduced plastic usage. The combination of barrier protection and flexibility makes them an industry standard for high-end skincare and sunscreen packaging.

Conclusion

5-layer flexible tubes outperform single-layer and aluminum laminate tubes in terms of barrier protection, durability, and user experience. For sunscreen packaging, they provide superior UV resistance, oxidation prevention, and long-lasting protection of active ingredients. As the demand for high-performance and sustainable packaging grows, 5-layer tubes will continue to shape the future of cosmetic packaging.

Are you looking for the best sunscreen packaging solution? Explore 5-layer flexible tubes to enhance your product’s performance, protection, and sustainability!

 

With over 20 years of expertise, Xingyuan Plastic is a trusted Chinese manufacturer specializing in cosmetic packaging materials, particularly plastic containers (PET, PP, acrylic). We deliver end-to-end solutions from custom design and R&D to production, offering diverse products like airless bottles, skincare bottles, hair care bottles, and sustainable packaging (recyclable/PCR plastics). Our ISO-certified facilities ensure strict quality control, compliance with global standards, and on-time delivery, while our free design services help brands align packaging with market trends. Catering to skincare, makeup, and haircare industries, we combine innovation, agility, and eco-conscious practices to empower startups and established brands worldwide. Partner with us for reliable, cost-effective packaging that elevates your brand’s identity.