If you’re launching a skincare or cosmetics brand, this is the first major packaging decision you’ll face — and it’s one that most founders get wrong.
PE Coex, ABL, and PBL aren’t just acronyms. They’re fundamentally different materials with different barrier properties, cost structures, and aesthetic possibilities. Choosing the wrong one can compromise your formulation’s shelf life, inflate your costs, or make your brand look cheaper than it deserves.
PE Coextrusion Tubes
PE Coex (polyethylene coextrusion) tubes are the workhorses of the industry. They’re made entirely from plastic — multiple layers of polyethylene fused together during extrusion.
Best for: Lotions, creams, body washes, conditioners, sunscreens — anything that doesn’t contain volatile actives or fragrances that degrade with oxygen exposure.
Advantages:
- Most affordable tube option at scale
- Excellent squeeze recovery — the tube bounces back to shape
- Wide range of decoration options including offset, silk screen, and hot foil
- Available with EVOH barrier layer for enhanced protection
- Fully recyclable in mono-material configurations
Limitations:
- Lower barrier properties compared to ABL
- Not ideal for highly reactive formulations (retinol, vitamin C serums)
- Can absorb certain fragrance molecules over time
ABL — Aluminium Barrier Laminate
ABL tubes have a thin aluminium foil layer sandwiched between plastic layers. This creates a near-perfect barrier against oxygen, light, and moisture — the three enemies of sensitive formulations.
Best for: Pharmaceutical products, medicated creams, premium serums, retinol formulations, and any product where ingredient stability is critical.
Advantages:
- Superior barrier properties — blocks oxygen, moisture, and UV light
- Excellent for products with a 3+ year shelf life requirement
- Premium metallic appearance when decorated
- Dead-fold property — stays squeezed, reduces product waste
Limitations:
- Higher cost per unit than PE Coex
- Less squeeze recovery — can look “used” quickly
- Not easily recyclable due to multi-material structure
PBL — Plastic Barrier Laminate
PBL tubes replace the aluminium layer with a plastic barrier (usually EVOH). They offer a middle ground between PE Coex and ABL — better barrier than pure plastic, better recyclability than aluminium laminate.
Best for: Colour cosmetics, toothpaste, premium creams, and brands that want barrier protection with better sustainability credentials.
Advantages:
- Good barrier without aluminium — more eco-friendly positioning
- Better squeeze recovery than ABL
- Can be decorated to look identical to ABL
- Growing preference among European and Asian export markets
Limitations:
- Barrier is good but not as absolute as ABL
- Slightly more expensive than PE Coex
- EVOH layer complicates recycling (though better than aluminium)
How to Choose
Here’s my rule of thumb after launching 500+ SKUs:
- Budget-conscious, stable formulations: PE Coex with EVOH
- Pharma or highly sensitive actives: ABL, no question
- Premium cosmetics with sustainability goals: PBL
- D2C brands starting out at 1K-5K units: PE Coex (lowest MOQ and cost)
The material you choose today will affect your margins, your brand perception, and your product’s shelf life for years to come. Don’t let a sales rep choose for you — understand the science behind it.
Want to learn material science in depth? Enroll in the Masterclass — Module 2 covers this with real-world cost comparisons.