5-Layer vs. 2-Layer Tubes: Why Your Formula Might Need the Upgrade

Introduction

To the naked eye, a 2-Layer PE Tube and a 5-Layer EVOH Tube look identical. They are both plastic. They are both flexible. They both hold cream.

So, why does the 5-Layer tube cost 10-15% more? And why do our engineers insist on it for certain products? The answer is invisible: Oxygen.

If you are launching a simple body wash, a 2-Layer tube is fine. But if you are launching a high-performance serum, choosing the wrong layer structure could destroy your formula before it even reaches the shelf.

Here is the science of "The Barrier."

1. The Structure: What is inside the wall?

Imagine cutting the tube wall in half and looking at it under a microscope.

• 2-Layer Tube (Standard PE):

  • It is essentially just Polyethylene (PE).

  • The Problem: PE is porous on a molecular level. Oxygen can slowly drift in, and volatile scents (like citrus oil) can slowly drift out.

  • Think of it like: A cotton t-shirt. It covers you, but the wind goes right through.

• 5-Layer Tube (EVOH Co-ex):

  • Layer 1: PE (Outer)

  • Layer 2: Adhesive (Glue)

  • Layer 3: EVOH (The Shield)

  • Layer 4: Adhesive (Glue)

  • Layer 5: PE (Inner)

  • The Hero: EVOH is a resin that blocks oxygen, gas, and chemicals.

  • Think of it like: A Gore-Tex rain jacket. Nothing gets in, nothing gets out.

2. The "Must-Have" List: When do you NEED 5 Layers?

If your ingredient list contains any of the following, you must use a 5-Layer tube. Do not gamble with 2-Layer.

• A. Active Ingredients (Retinol / Vitamin C):

  • These are highly unstable. If oxygen touches them, they oxidize (turn brown) and lose potency. A 5-Layer tube keeps them potent for 2+ years.

• B. Sunscreens (SPF):

  • Chemical filters in sunscreens are aggressive. They can actually "eat" into standard plastic, making the tube swell or become sticky. EVOH prevents this reaction.

• C. Strong Natural Oils (Tea Tree / Citrus / Lavender):

  • Essential oils are volatile. In a 2-Layer tube, the scent will migrate through the plastic wall. After 6 months, your lemon cream will smell like nothing.

3. The "Squeeze" Test

Besides protection, there is a physical difference.

• 2-Layer: Feels very soft and "floppy."

• 5-Layer: Feels slightly stiffer and more premium. It has better "Memory" (it bounces back to its round shape faster after squeezing).

Conclusion: Cheap Packaging is Expensive

If you save $0.02 per tube by choosing 2-Layer, but your entire batch of Vitamin C serum turns yellow in 3 months, you haven't saved money—you've lost your brand reputation.

The Rule of Thumb:

• Basic Wash / Lotion: 2-Layer is perfect.

• Active Skincare / SPF: 5-Layer is mandatory.

Not sure if your ingredients are aggressive? [Send us your formula for a Compatibility Test]