How to Choose the Right Cosmetic Tube for Sunscreen

Choosing the right sunscreen tube packaging is about more than appearance. The tube needs to work with the sunscreen formula, provide reliable dispensing, support your brand design, and protect the product throughout storage, transportation, and daily use.

For sunscreen brands, skincare companies, and private-label manufacturers, factors such as tube material, barrier performance, capacity, diameter, closure, decoration, and sustainability should all be considered before placing a bulk packaging order.

In this guide, we explain how to choose the right cosmetic tube for sunscreen and compare the most common packaging options.

1. Start with Your Sunscreen Formula

The first step is understanding the formula that will be filled into the tube.

Sunscreen products can vary significantly in viscosity and formulation. Some are thick creams, while others are lightweight lotions, gels, or emulsions.

Before selecting the packaging, consider:

• Product viscosity

• Formula ingredients

• Sensitivity to light or oxygen

• Required shelf life

• Filling temperature

• Compatibility between the formula and packaging material

Packaging compatibility testing is recommended before mass production, especially when developing a new sunscreen formula.

The goal is to make sure the tube maintains its appearance, sealing performance, flexibility, and dispensing function throughout the product's intended shelf life.

2. Choose the Right Sunscreen Tube Material

PE, ABL, and PBL are three common materials used for cosmetic tube packaging. Each structure offers different characteristics.

PE Cosmetic Tubes

PE cosmetic tubes are widely used for skincare, body care, cleansers, lotions, and sunscreen products.

They are soft, squeezable, lightweight, and available in different structures, including single-layer and multi-layer tubes.

PE tubes are suitable for brands looking for:

• A soft and comfortable squeezing experience

• Flexible customization

• Different surface finishes

• Various printing options

• Cost-effective packaging for medium and large production runs

Multi-layer PE structures can also be considered when additional protection is required.

ABL Cosmetic Tubes

ABL tubes, or Aluminum Barrier Laminate tubes, contain an aluminum barrier layer within the laminated structure.

They are often considered when a formula requires stronger protection against external factors such as light, oxygen, or moisture.

ABL sunscreen tubes can be a suitable option for formulas where barrier performance is an important packaging requirement.

They also offer a smooth surface for detailed graphic designs and are commonly used for sunscreen, skincare, pharmaceutical, oral care, and personal care packaging.

PBL Cosmetic Tubes

PBL tubes, or Plastic Barrier Laminate tubes, use a plastic-based multilayer structure.

They combine good barrier properties with the appearance and flexibility of plastic packaging.

PBL sunscreen packaging can be considered by brands looking for:

• Smooth tube appearance

• Good printing performance

• Flexible squeeze characteristics

• A plastic-based laminated structure

• Premium skincare positioning

The best material should ultimately be selected according to your formula requirements, target market, budget, and desired packaging appearance.

3. Select the Right Tube Capacity

Sunscreen tubes are available in many capacities, from small travel sizes to larger family-size products.

Common options include:

10–30 ml

Suitable for:

• Face sunscreen

• Travel sunscreen

• Samples

• Trial-size products

• Premium skincare collections

30–50 ml

This is a popular size range for facial sunscreen and daily sun care products.

It offers a good balance between portability and product capacity.

50–100 ml

Suitable for:

• Face and body sunscreen

• Daily sunscreen

• Outdoor sun care

• Standard retail packaging

100–200 ml

Often used for:

• Body sunscreen

• Beach sunscreen

• Family-size products

• High-volume sun care products

Capacity alone does not determine the final tube dimensions. Tube diameter and body length should also be adjusted according to the product design and filling requirements.

4. Consider Tube Diameter and Dispensing Experience

Tube diameter influences both appearance and usability.

A thicker sunscreen cream may require a suitable tube diameter and dispensing orifice so consumers can squeeze the product out comfortably.

A lightweight lotion may work with a smaller dispensing opening for better control.

When developing custom sunscreen tube packaging, consider:

• Product viscosity

• Desired dispensing amount

• Tube capacity

• Tube diameter

• Orifice size

• Overall packaging proportion

A good sunscreen package should make daily application convenient while helping reduce unnecessary product waste.

5. Choose the Right Closure

The closure is another important part of sunscreen packaging.

Flip-Top Cap

Flip-top caps are commonly used for sunscreen because consumers can easily open and close the tube during daily use.

They are especially practical for larger sunscreen and body care tubes.

Screw Cap

Screw caps provide a simple and clean appearance and can be suitable for facial sunscreen, skincare, and premium cosmetic products.

Special Applicators

Some sunscreen and skincare products may use special applicators or dispensing systems depending on the formula and positioning.

When choosing a closure, evaluate:

• Ease of opening

• Leakage resistance

• Dispensing control

• Cap-to-tube compatibility

• Consumer experience

• Brand appearance

6. Think About Light Protection

Some sunscreen formulations may benefit from packaging that helps reduce exposure to light.

Instead of choosing a transparent tube simply for appearance, brands should evaluate whether the formula requires an opaque or higher-barrier packaging structure.

Options can include:

• Opaque PE tubes

• Multi-layer PE tubes

• ABL tubes

• PBL tubes

• Colored cosmetic tubes

The final packaging structure should always be confirmed through appropriate compatibility and stability testing with the actual sunscreen formula.

7. Decide on Printing and Decoration

Packaging plays an important role in communicating your sunscreen brand's positioning.

Custom cosmetic tubes can support different decoration methods, including:

• Offset printing

• Silk screen printing

• Hot stamping

• Labeling

• Matte finish

• Glossy finish

• Custom colors

For minimalist skincare brands, a matte tube with simple screen printing can create a clean and modern appearance.

For premium sunscreen products, metallic hot stamping or detailed printing can help create stronger shelf impact.

When requesting a quotation from a sunscreen tube manufacturer, sending your artwork or packaging reference can help the supplier recommend the appropriate printing process.

8. Consider Sustainable Sunscreen Packaging

Sustainability has become an important consideration for many beauty and skincare brands.

Depending on your packaging requirements, possible options can include:

• PCR plastic tubes

• Reduced-plastic structures

• Recyclability-oriented PE packaging

• Sugarcane-based plastic options

• Lightweight packaging designs

However, sustainability should not be evaluated by material name alone.

Brands should also consider product compatibility, packaging weight, transportation, local recycling infrastructure, decoration, closures, and the overall packaging structure.

The right solution should balance sustainability with product protection and manufacturing feasibility.

9. Test the Packaging Before Mass Production

Before confirming a large order, brands should test the sunscreen tube with the actual formula whenever possible.

Important tests may include:

• Formula compatibility

• Leakage performance

• Sealing performance

• Drop testing

• Printing adhesion

• Cap fitting

• Filling performance

• Storage stability

Testing is particularly important when using a new formula, new tube material, or new closure system.

A packaging sample that looks good is not enough—the packaging must also perform reliably after filling.

PE vs ABL vs PBL: Which Tube Is Better for Sunscreen?

There is no single tube material that is best for every sunscreen product.

Instead of selecting packaging based only on price, consider your formula, target positioning, order quantity, decoration requirements, sustainability goals, and required barrier performance.

How to Choose a Sunscreen Tube Manufacturer

A reliable supplier should be able to help you evaluate more than just tube color and size.

When contacting a custom sunscreen tube manufacturer, provide as much information as possible, including:

• Product type: sunscreen cream, lotion, or gel

• Required capacity

• Preferred tube material

• Tube diameter

• Tube color

• Cap type

• Printing or decoration

• Order quantity

• Artwork

• Target market

Providing these details allows the packaging supplier to recommend a more suitable tube structure and prepare a more accurate quotation.

Looking for Custom Sunscreen Tube Packaging?

Choosing the right tube can help improve product protection, dispensing experience, brand presentation, and overall customer experience.

Yatjun provides custom cosmetic tube packaging for sunscreen and skincare products, including PE, laminated, and sustainable packaging options with different sizes, colors, closures, and decoration solutions.

If you are developing a new sunscreen product, send us your required capacity, material, quantity, artwork, and packaging requirements.

Our team can help you evaluate a suitable sunscreen tube solution and prepare samples and a quotation for your project.

Contact us for custom sunscreen tube samples and pricing.