Cosmetic packaging solutions come in numerous shapes, sizes, and materials but squeeze tubes have gained a unique presence in the beauty scene. Over the decades, many local and international brands have adopted these portable and flexible tubes.

Despite their importance, mastering the art of how to fill squeeze tubes may challenge many brands. Moreover, many brands are confused between manual and automatic filling options.

What Are Squeeze Tubes?

Squeeze or collapsible tubes are a type of flexible cosmetic packaging. They have a cylindrical shape. Squeeze tubes are mainly plastic, but you can find aluminum squeeze tubes. Plastic squeeze tubes are made of PE and PP, which give them flexibility and affordability. Aluminum Squeeze tubes, on the other hand, have a high-end appearance. Generally, both of them are safe and recyclable materials.

Squeeze tubes are versatile because you can use them with cosmetics, skin care products, and even pharmaceuticals. Moreover, they provide a waste-free application on the skin. These tubes also accommodate various formulas and viscosities, from serums, and gels to creams.

How to Fill Squeeze Tubes

If you want to efficiently fill your squeeze tubes, you should rely on automatic machines. These machines provide efficiency, accuracy, consistency, and optimal functionality.  Most filling machine systems are easy to get around and don’t require complex steps to operate.

How Squeeze Tube Machines Work

If you have some insight into how to fill cosmetic tubes, finding a solution for squeeze tubes won’t be a major challenge. Before understanding how to fill squeeze tubes, you need some basic knowledge of how their machines work. Generally, squeeze tube filling machines work similarly. However, they may vary in their designs, capacities, and overall features. Their similar working principle includes the following steps:

1. You can start by manually loading the empty tubes into the machines. For semi-automated machines, you’ll also place them into their designated filling stations or holders.
2. Conversely, fully automated machines will feed the statins with the tubes.
3. For semi-automated units, ensure that the tubes are placed with the open end (tail), which will be later sealed, facing the filling nozzle.
4. The machine will handle the filling and transfer tubes to the sealing station. In the case of using a semi-automated machine, you will have to manually move the tubes.
5. The sealing mechanism differs based on the tube’s material. For instance, plastic squeeze tubes are sealed using heat. Aluminum tubes, on the other hand, are pinched. Some machines combine two sealing techniques for plastic tubes, such as compressed air and heating.
6. Before ejecting the filled and sealed tubes, your machines will remove any extra sealing material.
7. Some machines are equipped with printing functions. They can print the batch number before the ejection phase. Other more advanced machines can print labels too.

Manual vs. Automated Squeeze Tube Filling

When you consider the options for how to fill squeeze tubes, there are two of them: manual and automated methods. Manual filling fits experimental purposes and very small production. Meanwhile, automated squeeze filling is more appropriate for large batches and mass production.

Manual Filling

This process excludes automated or semi-automated machines from the production process. It exclusively relies on pouring the product into the tubes using tools, such as manual pumps and syringes. This method has a few pros and a handful of downsides.

Pros

• Affordable Costs: There are only primitive tools, such as syringes and funnels. Also, you don’t have to pay for regular maintenance. However, you must pay for the professional labor to do the filling.
• Easy Setup: Manual filling doesn’t require any technical knowledge. The tools are easy to use and clean.

Cons

• Time-consuming Process: Using manual methods takes much time to fill a single tube
• Inconsistent Results: Your cosmetic squeeze tubes might not have the same filling level. Also, some tubes might contain air.
• Waste: Manual methods allow for spillage in large quantities, which can load more costs on your business.
• Hygiene Issues: Hygiene considerations and prerequisites can vary from one location to another. But in general, the manual filling of cosmetic tubes exposes cosmetics and personal care products to more air and light than the automated process.
• Incompatibility with Large Orders: While you can experiment with manual filling on a small scale, it won’t be efficient for large quantities and tight production schedules.

Automatic Filling

Using automated machines to fill your cosmetic tubes has plenty of perks. When done correctly, it can take your beauty business to a whole new level. However, nothing is perfect. This technique can have a few cons too.

Pros

• Fast production: Filling machines vary in their production capacity. But in general, all of them are fast. For instance, some machines can fill up to 120 or 150 tubes per minute. The capacity of manual filling, on the other hand, is variable and depends on the worker’s own conditions. But it usually takes at least 2 or 5 minutes to fill a single tube. This rate varies according to a person’s speed and the product’s nature.
• Dual Function: Many automated filling machines combine two functions: filling and sealing. This double functionality minimizes time waste and human intervention.
• Consistent Performance: Squeeze tube filling machines ensure the same level of filling, as there’s no room for human error.
• Versatility: Automated machines can accommodate various products with different viscosities, from gels to creams. All it takes is a simple tweak in the machine’s settings.

Cons

• Higher cost: Machines are expensive because they are fast and require minimal human intervention.
• Required Maintenance: This is a mandatory requirement to keep your production line on track. The cost may involve cleaning or replacing certain machine components.

Squeeze Tube Structure

The design of squeeze tubes is simple. It consists of 4 parts:

1. Head: This is the top part of cosmetic squeeze tubes. You can call it the tube’s neck too. It ends with the tube’s opening, where the product comes out. Different closures, caps, and applicators can be attached to a tube’s head. These applicators include:

• Roll-on: This allows users to directly apply the product on the desired spot. These tubes have one or more roller balls for optimal product distribution without touching the product. Roll-on applicators work best with water-based cosmetics, for example, eye serums.
• Nozzle: Squeeze tube nozzles have a narrow design to ensure waste-free application. Your consumers will get precise dosages of their favorite creams.
• Brush: This applicator is designed for eyelash care with serums and mascara.

As for closures, you can find:

• Flip-top Caps: It’s a very common closure type for cosmetic squeeze tubes. Users can easily flip it to apply to the product (cream or lotion). It also minimizes exposure to airborne contaminants.
• Twist-off Caps: Their mechanism relies on twisting and pulling the cap. They come with a one-time (tamper-evident) seal.
• Screw Caps: They rely on a continuous thread technique. Users rotate these caps multiple times to open or close.

2. Shoulders:They connect the head to the tube’s body. Moreover, they guide the product smoothly from the body to the neck.
3. Body: This is the largest component of the tube and where the product resides. It has a cylindrical shape and its outer surface accommodates labels and other customization options.
4. Tail:This is the bottom part of any squeeze tube. It is sealed after filling the tube. It can take different shapes due to different techniques, such as hot sealing and crimping techniques.

Knowing how to fill squeeze tubes is essential for your brand’s journey. Proper filling affects the product’s quality and the consumer’s reception of it. While manual filling appears as a cost-effective solution, it won’t maintain the quality you seek. Conversely, automatic filling adds value to your production line.

The same rules can apply to questions regarding how to fill cosmetic tubes. So, knowing the differences between manual and automatic options is mandatory. Also, realizing their impact on your brand lets you make a suitable decision.