Packaging Pitfalls: Top 3 Watchouts for Cosmetic Tubes
Cosmetic tube packaging is increasingly popular across beauty and personal care categories. A thoughtfully designed tube can make your product stand out, while poor execution may lead to functional problems, unhappy customers, and damage to your brand's reputation. However, cosmetic tubes pose unique challenges that can impact their quality, durability, and compatibility.
Below, we outline the top three challenges associated with cosmetic tubes, their potential impact on your brand, and strategies to address them effectively.
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1. Material Incompatibility with Product
Material incompatibility is one of the most common risks with tube components. When the material interacts negatively with the formula inside, it can lead to bulk migration through the tube walls, weight loss, and compromised product integrity.
Implications
- Weight loss due to migration through the tube sleeve.
- Product contamination or changes in formula stability.
- Reduced shelf life, leading to dissatisfied customers.
How to Avoid
Conduct a material science analysis to assess potential interactions between the tube sleeve material and the product formula. Recommendations may include adding a barrier layer, such as EVOH, or opting for a polyfoil sleeve or an all-aluminum tube for enhanced protection. Always confirm material compatibility through rigorous package compatibility testing.
2. Decoration Adhesion or Compatibility Failures
The appearance of your cosmetic tubes plays a key role in product presentation, but decoration failures can damage a customer’s perception of quality. These issues can arise either due to poor adhesion of the decoration or chemical interactions between the product and decoration.
Implications
- Adhesion failure can cause the decoration to peel or wear off, impacting visual appeal.
- Compatibility failure occurs when the product interacts with the decoration, leading to damage over time.
How to Avoid
Test all decoration methods, including hot-stamping, silk-screening, heat-transfer labels, and offset-printing, for both adhesion and compatibility. If issues arise, consider modifying curing properties, dwell times, or the chemical composition of inks and foils. Adding a UV-cured topcoat may also help isolate the decoration from the formula.
3. Insufficient Overflow Capacity (OFC)
Overflow capacity (OFC) is critical for ensuring accurate label claims and avoiding consumer dissatisfaction. An undersized tube that doesn’t account for necessary headspace or crimping requirements can result in packaging that fails to meet label claims.
Implications
- Regulatory penalties and loss of consumer trust if the packaging appears underfilled.
- Increased production costs due to redesigns or reworks.
How to Avoid
Start by specifying your intended label claim and choosing the appropriate tube diameter, whether round or oval. Calculate the required tube length, making sure to include the additional length needed for crimping. Collaborate with a packaging pro to ensure the tube size aligns with your product’s volume requirements.
By proactively addressing these three risks—material incompatibility, decoration issues, and overflow capacity—you can create reliable and appealing cosmetic tube packaging that resonates with consumers and strengthens your brand.
Work with a Packaging Pro to avoid common packaging pitfalls for your component types
About the Author
Scott is an award-winning package development professional with 30+ years of multi-industry experience. A seasoned packaging expert with extensive experience in beauty and cosmetics, Scott led packaging innovation for the makeup category at Estée Lauder, driving projects from concept to launch in lip, foundation, primer, and makeup / skincare hybrid packaging. Before that, he directed package development for Tom Ford Beauty, overseeing luxury packaging in fragrance, makeup, and skincare. With expertise spanning all cosmetic packaging materials and processes, Scott has a strong background in project management, packaging development, and on-site production across global facilities.
Scott Roman | Ventus Packaging Solutions LLC |Sroman@ventuspack.com
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