Key takeaways
- There are three types of tubes used in industrial packaging: aluminum, plastic, and laminated (multilayer plastic/aluminum).
- The aluminum tube provides a complete barrier and prevents any air from entering: it is the ideal choice for solvent-based adhesives and oxidation-sensitive products.
- Plastic tubing offers durability, aesthetic appeal (transparency, Euro-hole), and affordability, at the cost of a more limited barrier.
- Laminated tubes combine barrier protection with a premium look: an excellent solution for sensitive products with a strong brand identity.
- Etraves packages all three types of tubes (diameters ranging from 13.5 to 50 mm) and assists you in selecting the right container, including compatibility testing.
Adhesives, sealants, greases, technical gels, and assembly pastes: for all these products, the flexible tube remains the standard packaging format, valued for its precise dispensing, convenience, and compact size.
But the term “tube” actually encompasses three types of containers with very different properties: aluminum tubes, plastic tubes, and laminated tubes.
The choice of material directly affects the product’s shelf life, its appearance on the shelf, its production cost, and even its recyclability. In this article, we compare these three types of tubes to help you choose the right container for your product—from the perspective of a contract packager who fills tubes made of all kinds of materials for manufacturers every year.
The tube: a key format in contract packaging
Before comparing materials, let's review why tube packaging is so appealing to manufacturers of technical products. The tube protects the product from air and light, allows for precise dosing thanks to its nozzle, closes easily between uses, and fits just as easily into a toolbox as it does on a supermarket shelf.
Available in sizes ranging from small, handy tubes to large, professional-grade tubes, with diameters ranging from 13.5 to 50 mm, it is suitable for adhesives and sealants as well as greases, gels, and paste-like formulations.
On the production side, the tube filling is done from the back of the tube, before it is permanently sealed: crimping for aluminum, welding for plastic and laminate. It is precisely at this stage that the choice of material becomes crucial, as it determines the sealing equipment, the decorative options, and the product’s final protection.
The aluminum tube: the ultimate barrier
The aluminum tube offers the best possible protection for a sensitive product. The metal acts as a complete barrier against oxygen, moisture, UV rays, and odors: nothing gets in, nothing gets out. Another key advantage: the aluminum tube is a “dead” tube, meaning it remains deformed after each squeeze. The product is therefore never recontaminated by air re-entry, unlike a plastic tube, which returns to its original shape by drawing in ambient air. This is why solvent-based adhesives, oxidation-sensitive products, and long-shelf-life formulations are traditionally packaged in aluminum.
Aluminum tubes are also economical and lightweight, with an interior that is typically protected by a coating compatible with the packaged product. Their drawbacks include a more industrial appearance, susceptibility to bending—which can leave marks on the tube on store shelves—and the inability to see the product through the container. For this reason, aluminum tubes are often placed in a box or blister pack to protect them.
For a technical product sold to professionals, these constraints are of little consequence compared to the product’s durability; for a consumer product with a strong brand image, however, they may lead to the selection of other materials.
Plastic Pipe: Strength, Aesthetics, and Cost
Plastic tubes (polyethylene or polypropylene) stand out for their mechanical strength and how they look on the shelf. They don’t bend or get dented, return to their original shape after each use, and maintain a flawless appearance throughout their shelf life—a real selling point for self-service products.
It also allows for transparency, which is valuable when the product's color or texture is a selling point, and lends itself very well to decoration: screen printing, labeling, and printing.
The tube is sealed by a simple weld at the back, which can include a Euro-hole for hanging on pegs in hardware store aisles. Its low cost and ease of production make it the preferred choice for mass-market products. Its main limitation remains its permeability: the plastic slowly allows oxygen and moisture to pass through, and as the tube springs back into shape, it draws in a small amount of air with each squeeze.
The laminated tube: the hybrid compromise
The laminated tube is a hybrid container made from multilayer sheets that alternate between plastic and aluminum. It thus combines the best of both worlds: the barrier properties of aluminum, provided by a thin metallic layer embedded in the wall, and the flexibility, strength, and decorative qualities of a plastic tube.
For manufacturers, laminated tubing allows them to package products that are sensitive to moisture or oxygen while still offering a tube that is pleasant to use and looks appealing on the shelf. It can be heat-sealed like plastic tubing and supports high-quality printing across its entire surface. Its cost falls between that of aluminum and plastic, but its multilayer structure makes it more difficult to recycle than a single-material tube—a factor to consider, especially as European packaging regulations (PPWR) mandate recyclable packaging by 2030.
Comparison Chart: Aluminum, Plastic, or Laminate
| Criterion | Aluminum tube | Plastic tube | Laminated tube |
|---|---|---|---|
| Air/Moisture Barrier | Total | Limited | Very good |
| Air Intake During Use | None (dead tube) | Yes (getting back in shape) | Low |
| Appearance on the shelf | Can be marked | Flawless; transparency is possible | Impeccable, high-end decor |
| Closure | Crimping | Welding (Euro hole possible) | Welding |
| Recommended Products | Solvent-based adhesives, oxidation-sensitive products | Water-based adhesives, gels, mass-market products | High-profile, brand-sensitive products |
| Cost | Economic | The most economical | Intermediate |
| Recyclability | Good (recyclable metal) | Good if it's made of a single material | More difficult (multilayered) |
Which tube is right for your product?
In practice, the decision is made by considering three factors.
1/ Is your product sensitive?
A product that contains solvents, is sensitive to oxygen or moisture, or is intended for long-term storage should be packaged in aluminum—or in laminate if the image is important.
2/ How will it be used?
Repeated use with successive dosages does not work well with a plastic tube that allows air to enter for sensitive formulations, whereas an aqueous gel works perfectly in this situation.
3/ Where will it be sold?
In self-service settings, the appearance of the plastic or laminated tube and the option of a Euro-hole make all the difference; in professional settings, shelf life takes precedence.
There is therefore no “best” tube in absolute terms: there is a tube suited to each product-market combination. That’s precisely why it’s so important to work with a packaging specialist who is well-versed in all three areas: compatibility testing between the product and the container, conducted early in the process, allows you to validate your choice before starting production. This approach follows the same logic as choosing between a cartridge, a bottle, or a can for other product lines: the product dictates its container, never the other way around.
Etraves: Your Partner for Tube Packaging
Based in France, Etraves is a contract packaging company specializing in technical products: adhesives, sealants, silicones, greases, and two-component formulations. Our filling lines process aluminum, plastic, and laminated tubes ranging in diameter from 13.5 to 50 mm: back-end filling, crimping or welding, capping, labeling, or cartoning, through to logistics preparation.
Our team will advise you on choosing the right tube for your product, conduct compatibility tests, and manage everything from small launch runs to high-volume production. Are you unsure whether to choose aluminum, plastic, or laminate for your next product?
Contact us to discuss your project and receive a customized quote.
FAQ – Plastic, Aluminum, or Laminated Tubing
What is the difference between an aluminum tube and a plastic tube?
The key difference lies in the barrier properties and the behavior of the tube. Aluminum completely blocks oxygen, moisture, and light, and remains deformed after each squeeze: the product never comes into contact with air that has been drawn back in. Plastic tubes, on the other hand, return to their original shape by drawing in a small amount of air with each use and slowly allow oxygen to pass through their walls. On the other hand, they are more durable on store shelves, can be transparent, and are generally less expensive. The choice therefore depends on the sensitivity of the packaged product.
What is a rolled tube?
A laminated tube is made from a multilayer sheet consisting of alternating layers of plastic and a thin layer of aluminum, which are welded together to form the body of the tube. This hybrid structure combines the barrier properties of metal with the flexibility of plastic: the product is well protected from air and moisture, while the tube remains easy to squeeze and offers a high-quality printing surface.
Which tube should you choose for glue or sealant?
For solvent-based adhesives, contact adhesives, or oxidation-sensitive products, the aluminum tube remains the best choice: its complete barrier and the absence of air ingress preserve the product’s qualities throughout its shelf life, even after multiple uses. For water-based adhesives, gels, or consumer-grade emergency sealants, the plastic tube offers an excellent balance of convenience and value, with an attractive appearance on store shelves. Laminated packaging is a good option when you need to balance product protection with a premium brand image.
Are the tubes recyclable?
Aluminum tubes are easily recyclable, as the metal can be recycled indefinitely once collected. Single-material plastic tubes (particularly polyethylene) can also be incorporated into existing recycling streams. Laminated tubes present the greatest challenge: their multilayer structure, which combines plastic and aluminum, makes it difficult to separate the materials. This issue is becoming increasingly important with the European PPWR regulation, which mandates recyclable packaging by 2030: a custom packaging manufacturer can help you anticipate these changes when selecting your tubes.
