This article briefly introduces the cost reduction methods of cosmetic tube packaging

Introduction: As packaging sourcing and supply chain managers in the cosmetics industry, achieving technical cost reductions for soft tube packaging without sacrificing quality requires a more comprehensive strategy than for glass bottles. Flexible tubes are multilayer composite materials (typically plastic/aluminu m foil/plastic + ink + coating), involving multiple processes such as coextrusion, printing, and tube making. Cost reduction potential exists at multiple stages. This article provides in-depth technical reference and decision- making support for purchasing partners.

ONE

Technical directions and measures for the core cost reduction of cosmetic tube

While ensuring core quality attributes such as barrier properties (preventing deterioration of contents and loss of aroma), mechanical strength (compression resistance, bending resistance, and drop resistance), sealing, printing quality, and user experience (extrudability and feel), waste is eliminated and efficiency is improved through design optimization, material innovation, process upgrades, and standardization. The following details cost reduction measures, implementation paths, and key points for cosmetic tube packaging from the product technology perspective:

1. Structural optimization and lightweighting:

Thinning of tube walls: Goal: To reduce the amount of material used per unit length or unit weight. Measures: Working closely with suppliers, utilizing advanced co-extrusion technology and precision molds, while ensuring key performance (barrier properties, stiffness, and pressure resistance), try to thin each functional layer (especially the PE/PP layer). The key point is: Barrier layer optimization: The aluminum foil layer or EVOH barrier layer is the core, and thinning must be done with extreme caution. Strict accelerated aging tests (high temperature, light) are required to verify whether the barrier capacity to oxygen, water vapor, ultraviolet rays, and specific ingredients (such as essential oils, active ingredients) after thinning meets the standards. Consider using thinner but more efficient aluminized film or high-barrier transparent film to replace part of the aluminum foil demand (see Material Innovation).

Thinning of inner and outer layers: The PE/PP layer is the main target for thinning. It is necessary to ensure that after thinning: the tube body has sufficient stiffness to prevent collapse and deformation during transportation and shelf life. Maintain good bending resistance (especially the shoulder and tail) to avoid repeated bending and cracking. Meet the tail sealing strength requirements (heat sealing strength). Ensure good extrusion properties. Too thin tube wall may lead to extrusion difficulties or "rat tail" phenomenon. Optimize layer thickness distribution: Use simulation analysis to identify stress concentration areas (such as shoulder turning points and tube tail sealing areas), thin in non-critical areas, and maintain or slightly increase thickness in critical areas.

Tube Dimension Optimization: Reduce Redundant Space: Accurately calculate the content capacity and reserved space (dead space) to optimize the tube diameter and length ratio. Design the most compact tube shape while meeting filling requirements (filling head size, filling accuracy) and consumer experience (ease of extrusion and grip), minimizing surface area and material usage. Simplify the tube shoulder/tube head design: Avoid overly complex or heavy tube shoulder transitions. Optimize the tube shoulder shape and wall thickness distribution while ensuring cap fit, sealing, and aesthetics.

Tube tail optimization: Evaluate the most economical tail sealing method: Compare the cost (materials, energy consumption, efficiency) and performance (sealing, strength) of double-fold tail sealing, single-fold tail sealing, and flat tail sealing. Choosing a simpler tail sealing method may reduce costs while meeting sealing requirements.

2. Material innovation and substitution:

Cost-effective substrate selection: Evaluate different grades/brands of resin: Work with suppliers to evaluate more cost-effective PE, PP grades, or specifically formulated recycled materials (see below), while meeting performance requirements (such as melt index, density, and chemical resistance).

Exploring Mono-Material Structures: Replacing traditional multi-layer structures (such as PE/Al/PE) with a single polymer (e.g., all-PP) or a highly compatible polymer combination. This significantly improves recyclability (in line with ESG trends) and has the potential to simplify the structure and reduce costs (reducing the number of layers, simplifying lamination, and increasing recycled content utilization).

The challenge is that the barrier properties of all-plastic tubes are generally lower than those containing aluminum foil, requiring careful evaluation based on the characteristics of the contents (e.g., susceptibility to oxidation, light sensitivity) and shelf life requirements. High-barrier all-plastic tubes (e.g., with the addition of EVOH or special coatings) may be more expensive.

Ink and Coating Optimization: Reduce the Number of Colors/Simplify Print Design: Evaluate whether reducing the number of printed colors or adopting simpler pattern designs (e.g., reducing the full-page print area) can reduce ink costs, shorten print preparation time, and reduce solvent usage. Evaluate the most cost-effective ink systems: Compare the comprehensive costs (unit price, drying energy consumption, VOC treatment costs) of different brands/types of inks (solvent-based, water-based, UV), while meeting the requirements for friction resistance, migration resistance, content resistance, and color. Optimize Coatings: Evaluate the possibility of reducing or replacing the inner coating (leakage resistance, reaction resistance) and outer coating (wear resistance, scratch resistance, tactile feel), while ensuring that the functions are met.

Increase the use of recycled polymer (PCR): Goal: Reduce virgin material costs and enhance the company's sustainability profile (potentially leading to price premiums or policy support). Measure: Work with suppliers to include or specify the use of composite materials containing a certain percentage of high-quality, food/cosmetic-grade PCR resins (e.g., PCR-PE, PCR-PP) in their production processes. Key points include: Strict quality control: PCR materials must be reliably sourced and pure (free of contaminants and odors), possess stable properties (such as melt index, color, and impurities), and pass rigorous safety testing (heavy metals, migration, and allergenicity). Layer design: PCR materials are typically used in non-contact layers (middle or outer layers). Inner layers that come into contact with the contents must still use food/cosmetic-grade virgin materials to ensure safety. Color management: PCR materials are typically colored (primarily gray), and their impact on the final product's appearance must be considered. Darker tubes may allow for a higher PCR ratio.

High-barrier, lightweight alternative: Aluminum-coated film (VMCPP/VMPET) as a replacement for aluminum foil: Aluminum-coated film is thinner, lighter, and more flexible than pure aluminum foil, generally at a lower cost, and exhibits certain barrier properties. However, its barrier properties (especially to water vapor) and bending resistance (prone to pinhole formation) are generally lower than those of aluminum foil. Rigorous testing is required to verify whether it meets the protection needs of specific products. Transparent high-barrier film (such as reinforced EVOH, SiOₓ/AlOₓ coated film, PVA coated film): It meets the needs of products requiring transparent packaging while also providing good barrier properties. The cost may be higher, so a comprehensive evaluation is required.

3. Improvement of manufacturing process and efficiency:

Improving Printing and Laminating Efficiency: High-Speed Printing/Laminating: Utilizing more advanced printing presses (such as satellite gravure printers) and laminating machines increases production speed and reduces unit costs. Optimizing Overprint Accuracy: Reducing scrap caused by overprint misregistration. Low Solvent Residue/VOC Emissions: Optimizing the drying process reduces solvent usage and lowers environmental disposal costs. High-Precision, Long-Life Molds: Ensuring tube head size and shape accuracy, as well as the stability of the sealing mold, reduces defective products. Regular Maintenance: Ensures molds are in optimal condition.

Mold optimization and maintenance: Increase tube production speed: Upgrade tube production equipment to increase output per unit time. Reduce tail seal defect rates: Optimize heat sealing temperature, pressure, and time parameters, strengthen online testing, and reduce tube scrap due to loose tail seals, leaks, and deformation. Reduce tube head and tail scrap: Optimize tube cutting processes.

Tube manufacturing process optimization:

4. Standardization and generalization:

Unified tube head size/cap type:

· Implementing standardized tube head diameters and thread specifications within the company allows hoses of different product lines and capacities to use the same cap specifications (screw caps, flip caps, duckbill caps, etc.). This is one of the most effective cost-reduction measures, significantly reducing cap mold costs, procurement complexity, and inventory costs.

· Build a library of basic tube shapes: Design several basic tube shapes with standard diameters and shoulder shapes. New products will prioritize standard tube shapes, differentiated only by printed pattern, tube length (capacity), and tube head/cap design. This reduces the number and cost of new hose molds.

· Evaluate universal molds: If brand tone allows, consider using the supplier’s existing mature “public mold” tube type.

TWO

Implementation steps of the cost reduction for cosmetic tube

· Current situation analysis and baseline establishment:

· Record the specifications of all existing tubes in detail: structure (material and thickness of each layer), size (diameter, length, capacity), head type, cap specifications, weight, supplier, cost structure (material cost, processing cost, mold allocation), historical performance data (breakage rate, leakage rate, customer complaints).

· Build cost models and performance benchmarks.

· Goal Setting and Prioritization:

· Set specific goals based on cost reduction indicators (e.g., reduce unit cost by X%, achieve PCR usage ratio of Y%).

· Analyze existing tubes and rank them by purchase volume, cost contribution, cost reduction potential (e.g., currently significantly thicker wall thickness, complex structure, use of expensive barrier materials), and risk level (high-value/high-sensitivity products), prioritizing high-potential, medium- and low-risk pilot projects.

· Forming cross-functional teams:

· Core: Procurement/supply chain (leading), packaging R&D/technology (leading technical solutions), quality control/quality (standard control).

· Key support: Product development/R&D (content compatibility, shelf life requirements), marketing department (brand image, consumer acceptance), production department (filling line adaptability), regulatory department (material compliance, especially PCR).

· Technical solution design and supplier collaboration:

· Packaging technology proposes solutions based on the target (such as thinning solutions, structural replacement solutions, PCR application solutions).

· Key: Involve core tube suppliers early on. Suppliers possess in-depth knowledge of materials, processes, and equipment. Jointly evaluate the feasibility, cost savings potential, potential risks, and testing and verification plans.

·   Sample making and mold preparation:

· Finalize the details of the plan.

· Produce samples (may require new or modified compound dies, printing rollers, tube forming dies/punches). Evaluate tooling cost amortization.

·   Strict testing and verification: (Core guarantee without compromising quality!)

· Physical properties:

o Thickness measurement: Whether the actual thickness of each layer meets the design.

o Sealing test: tube tail sealing strength (heat seal strength), tube head and cap sealing (torque test, negative pressure/positive pressure sealing test).

o Barrier testing: Critical! Oxygen transmission rate and water vapor transmission rate testing (according to ASTM F1307, ASTM F1249, etc.) are required. Accelerated aging testing (e.g., 3-6 months at 40°C/75% RH, or even more stringent conditions) is required to simulate shelf life and detect changes in content weight, physical and chemical properties, aroma, and packaging appearance (e.g., delamination and deformation).

o Mechanical strength:

· Compressive strength: simulates stacking pressure (e.g. 1 meter high stacking for 1 week).

·Drop resistance: Drop tests at different heights and angles (empty tube, full tube).

·Bending resistance: The number of times the tube body (especially the shoulder) is repeatedly bent until it cracks.

o Extrusion test: Simulates consumer use to evaluate whether the extrusion force is appropriate, whether it is smooth, and whether there is a "rat tail" or interruption.

Filling line adaptability test: Test the smoothness and yield rate of processes such as tube loading, filling, sealing, capping, labeling, and boxing on a real filling line.

Transportation test: Simulate the actual logistics environment (vibration, drop, stacking) to test the entire box and evaluate damage, deformation, and leakage.

Adhesion test (tape test).

   Abrasion resistance test (dry and wet rub).

Content resistance test (e.g., whether lotions and creams will discolor or smudge after contact).

Printing performance:

Migration testing: New tubing is filled with the actual product or a simulant and stored under accelerated and/or ambient conditions to detect any migration of hazardous substances (particularly when using PCR materials or new coatings/inks). This test complies with relevant regulations such as EC No. 10/2011 (EU) and FDA CFR 21.

Sensory evaluation: Test the contents to see if any foreign odors are introduced.

Compatibility and safety testing:

Cost-Benefit Analysis and Decision Making:

Summarize test data to confirm that all key quality indicators meet standards.

Accurately calculate cost reductions (including material savings, efficiency gains, scrap reduction, potential logistics savings, and mold amortization).

Comprehensively assess technical risks, market risks (consumer acceptance, especially for cosmetic changes like replacing aluminum with all-plastic tubes), and switching costs, leading to decisions by the team and senior management.

Mass production introduction and continuous monitoring:

Confirm mass production specifications and quality standards with suppliers (e.g., tighter thickness tolerances, barrier properties spot checks, PCR content testing).

Develop a plan for the transition from the old version to the new version (using old inventory).

After mass production, closely monitor: supplier material quality, production line performance (especially filling and sealing), shipping damage rate, and market feedback (complaints related to tubes).

THREE

Key points to note when reducing cosmetic tube costs

· Barrier property is the lifeline:

·   Any material changes (thinning, replacing aluminum foil, using PCR) or structural simplifications must be verified through rigorous, long-term barrier and accelerated aging tests. This is the core of ensuring product shelf life and consumer safety and cannot be compromised.

· Content compatibility is the red line:

· New packaging materials (especially PCR, new coatings, new inks) must demonstrate chemical compatibility with the contents to ensure no harmful migration and comply with global regulatory requirements.

·   Deep cross-departmental collaboration: The full participation of R&D (content stability, testing standards), marketing (brand image, consumer insights), production (filling feasibility), and quality (test execution, standard control) is crucial.

· In-depth cooperation with strategic suppliers:

·   Tube technology is highly complex and rapidly evolving. We view our core suppliers as technical partners, leveraging their expertise in materials, processes, and testing. We strive to build transparent, trusting, and long-term relationships.

· Data-driven, testing is the King:

·   All decisions must be based on detailed test data, especially long-term stability data. Avoid drawing conclusions based on empiricism or short-term testing.

·   Balancing Lightness and Functionality:

·   Thinning and simplifying the structure cannot sacrifice the tube's stiffness, compression resistance, bending resistance, sealing, and good extrusion experience. Consumers have a low tolerance for hoses that are "soft," "unsqueezable," or "easily breakable."

·   A comprehensive view of PCR applications:

· Quality stability is a prerequisite: Ensure the PCR material source is stable, pure, and reliable. Establish strict supplier audits and incoming inspection standards.

· Regulatory compliance is fundamental: Meet target market regulations for the use of recycled materials in cosmetic packaging.

· Consumer communication: Consider how to communicate the environmental benefits of using PCR to consumers; this can become a marketing highlight.

·   Standardization of tube heads/caps is the point with the greatest leverage effect:

·   Focusing efforts on promoting standardization of internal tube heads can lead to significant reductions in cap costs and a simplification of the supply chain.

· Pay attention to the trend of mono-material pipes:

·   While the technical challenges are significant, its advantages in recyclability and potential costs (in the long term) are clear. We should closely monitor technological progress and conduct timely assessments.

·   Risk management:

· Take small steps and conduct gradual verification: For major changes (such as major material substitutions or high-ratio PCR), conduct a small-scale pilot program and fully verify them before rolling them out.

· Maintain a fallback plan: Prepare the ability to revert to the original solution if verification fails or problems arise during early mass production.

· Strengthen supply chain resilience: Assess the new solution's reliance on a single supplier and introduce alternative suppliers or solutions if necessary.

Summary

Technical cost reduction for hose packaging is a delicately balanced battle. The key lies in achieving systematic cost optimization through collaborative design (thickness reduction, optimization, and standardization), material innovation (cost-effective substrates, high-barrier alternatives, and PCR applications), process refinement, and in-depth supplier collaboration, all while maintaining the bottom line of barrier properties, safety, and functionality. The keys to success lie in rigorous testing and verification, seamless cross-functional collaboration, mutually beneficial relationships with strategic suppliers, and a zero-compromise approach to quality. This not only reduces costs but also enhances supply chain sustainability and future competitiveness.