ABL vs. PBL: Which is the Best Partner for Your Product?

Introduction

In the tube packaging world, there are two giants: ABL and PBL.

To the untrained eye, they look similar. But cut them open, and they are completely different animals.

Choosing the wrong one can lead to oxidized product (if the barrier is too weak) or a messy brand image (if the tube crinkles).

SampoX is here to decode the acronyms so you can make the right choice.

1. ABL (Aluminum Barrier Laminate): The "Ironclad Guardian"

The Structure:

Imagine a sandwich.

• Plastic (Outer)

• Aluminum Foil (Middle)

• Plastic (Inner)

  It combines the look of plastic with the protection of metal.

The Superpower: Ultimate Barrier

Nothing gets through metal foil. Oxygen, light, moisture, strong flavors—ABL blocks them all 100%.

Best For: Toothpaste, pharmaceutical ointments, hair dyes, and formulas with highly active/volatile ingredients (like Retinol or Vitamin C).

The Characteristic: "Dead Fold"

This is the defining feature of ABL.

When you squeeze it, it stays squeezed. It does not bounce back.

• Pros: Great for getting every last drop out. Gives a "clinical/pharmacy" vibe.

• Cons: The tube looks wrinkled and messy halfway through use. It can develop micro-cracks over time.

2. PBL (Plastic Barrier Laminate): The "Resilient Modernist"

The Structure:

An all-plastic sandwich.

• PE (Outer)

• EVOH (Middle Barrier)

• PE (Inner)

  We replaced the metal with EVOH (Ethylene Vinyl Alcohol), a high-tech transparent plastic resin that blocks oxygen.

The Superpower: "Memory" (Restitution)

PBL is like a memory foam pillow. When you squeeze it, it bounces back to its original round shape.

Best For: Premium skincare, lotions, conditioners, and sunscreens.

The Aesthetics:

• Printing: PBL is printed flat before the tube is formed. This allows for incredibly sharp, 360-degree graphics that look photographic.

• Look: Because it bounces back, the branding stays legible and pristine until the tube is empty. No ugly wrinkles.

3. The Sustainability Factor (The Tie-Breaker)

Here is where the market is shifting.

• ABL: Because it fuses plastic and metal together, it is extremely difficult to recycle. Most recycling plants consider it a contaminant.

• PBL: Standard PBL is better, but Mono-material PBL (Full PE) is the winner. If made correctly (with <5% EVOH), it can be recycled in the standard HDPE stream.

Summary: The Decision Checklist

Still not sure if your formula needs Metal or EVOH?

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