Tubes are a favourite pack for creams, gels, toothpaste, ointments and many cosmetic products. They protect the product, dispense it neatly and present the brand well on a shelf. Filling and sealing tubes is a specialised task that requires dedicated equipment, and choosing the right tube filling machine depends largely on the type of tube you use.
Types of Tubes
- Plastic tubes: made from polyethylene, common for cosmetics and personal care.
- Laminated tubes: made from multilayer materials that include a barrier layer, used for toothpaste and many creams.
- Aluminium tubes: offer an excellent barrier and are common for pharmaceutical ointments.
The sealing method depends on the tube material.
How a Tube Filler Works
Tubes are loaded into holders on a rotating table, usually with the open end facing upward. The machine orients the tube using an eye mark so that the printed design faces correctly after sealing. A nozzle descends into the tube and fills it with product, often using a piston pump. The tube end is then sealed, coded and trimmed, and the finished tube is ejected.
Sealing Methods
- Hot air sealing: hot air melts the inner surface of plastic or laminated tubes, and jaws press them together. It produces strong, attractive seals.
- Ultrasonic sealing: vibration creates heat to seal plastic and laminated tubes. It is fast and energy-efficient.
- Folding and crimping: aluminium tubes are folded several times and crimped to seal.
Product Considerations
Creams and gels can be viscous, temperature-sensitive or prone to trapping air. A jacketed hopper keeps the product at a suitable temperature, and a stirrer maintains consistency. Suck-back at the end of each fill prevents product from contaminating the seal area.
Coding
Batch numbers and dates are usually embossed into the seal during sealing. Some machines add printing systems for more information.
Hygiene and Materials
Contact parts should be SS 316 for pharmaceutical and cosmetic use. The hopper, pump and nozzle must be easy to dismantle for cleaning. For pharmaceutical ointments, documentation and qualification support are essential.
Speed and Automation
Semi-automatic machines suit small producers, with operators loading tubes by hand. Fully automatic machines load tubes from a magazine and run at higher speeds. Larger operations may integrate cartoning machines downstream.
Common Issues
- Leaking seals: check temperature, pressure and product in the seal area.
- Misaligned print: check eye mark sensor settings.
- Inconsistent fill weight: check product temperature and pump settings.
Tube Quality and Storage
Tubes that are dented, out of round or stored in humid conditions cause orientation and sealing problems. Store tubes in their original cartons in a clean, dry area, and check incoming batches for printing position and dimensional consistency. The eye mark position in particular must match what the machine expects; if a new tube supplier prints it slightly differently, the machine settings will need adjustment. Keeping a reference tube from each approved batch makes comparisons easy when problems appear.
Choosing a Machine
Consider your tube types, product viscosity, required output and compliance needs. Request a trial with your tubes and product.
Hilden supplies tube filling and sealing machines for cosmetic, pharmaceutical and food applications, and can help you choose a configuration that fits your tubes and production goals.
