Squeeze Tube Container

SampoX Unveils Custom Silicone Tip Lip Balm Tube with Client Demo




SampoX recently introduced its custom silicone tip lip balm tube designed for precision and ease of use. A satisfied client showcased the finished product with a demonstration of its smooth application, highlighting its premium quality and innovative design.



SampoX has announced its latest innovation in cosmetic packaging—a custom silicone tip lip balm tube meticulously engineered to meet the evolving demands of the cosmetics industry. The new tube features a precision silicone tip that guarantees a smooth, hygienic application, setting a new standard for lip balm packaging.

A satisfied client shared a demonstration video showcasing the product in its final form. In the video, the client highlights the elegant design and superior functionality of the silicone tip lip balm tube by applying the finished product on the lips. This visual presentation clearly reflects the tube’s outstanding quality and user-friendly design.

This launch underscores SampoX’s dedication to delivering customizable, eco-friendly packaging solutions that blend advanced technology with modern aesthetics. The custom lip balm tube not only enhances the user experience but also reinforces SampoX’s reputation as a leader in innovative cosmetic packaging. Stay tuned to our news page for more updates on our groundbreaking products and packaging solutions.



© 2025 SampoX. All Rights Reserved.

When purchasing cosmetic packaging tubes, one critical decision is how the product will be filled. There are two common approaches: pre-filling (before sealing) and post-filling (after tube production but before sealing). Each method has its ideal use case and equipment requirements.


1. Pre-Filling (Before Tube Sealing)
In this method, the soft tube is filled before the tail end is sealed. This is the most common practice in professional tube production lines.

Best for:



Medium to large-scale production



Brands with access to automated or semi-automated sealing equipment



Advantages:



Faster and more efficient for bulk quantities



Sealing and filling are integrated in the same production flow



Suitable for high-viscosity and heat-sensitive products



Considerations:



Requires a tail-sealing machine



Tube must remain upright after filling to prevent leakage before sealing




2. Post-Filling (Filling from the Nozzle End)
Also called top filling, this method involves filling the tube after the bottom has already been sealed. It’s often done manually or with a simple filling tool.

Best for:



Small-batch orders



Handmade or artisanal beauty products



Startups and labs without full-scale equipment



Advantages:



No sealing machine required



Ideal for sampling, testing, or low MOQ runs



Flexibility in filling multiple types of products in small volumes



Considerations:



Typically requires a special cap or applicator



Can be less efficient and slower for large orders




Conclusion
Choosing between pre-filling and post-filling comes down to your production setup, batch size, and whether you have sealing capabilities in-house. For startups, post-filling is a flexible entry point, while established brands generally opt for pre-filling to ensure consistency and speed.

Part 1: The Non-Negotiable - Chemical Compatibility Testing
This is the first and most critical line of defense against product failure.



What it is: A process that evaluates whether the packaging material (plastic, coating, applicator, seal) will chemically resist the formula without degradation, leaching, or causing formula instability.



Why it matters: Incompatibility can lead to discoloration, odor change, texture separation, loss of efficacy, and even contamination. (Recall: The TPE applicator corrosion case mentioned before).



SampoX Procedure:



Accelerated Aging: Filled samples are stored at elevated temperatures (e.g., 40°C, 45°C) for weeks to simulate months of shelf life.



Visual Inspection: Checking for crazing, cracking, cloudiness, or discoloration of the package and the formula.



Performance Check: Measuring the viscosity, pH, and color of the formula before and after testing.



Material Analysis: Using techniques like FTIR to detect any chemical migration.






Part 2: Putting the Package to the Test - Physical & Performance Tests
A package must survive the rigors of production, shipping, and daily use.








Test Type
Purpose
SampoX Method




Seal Integrity Test
Ensure the package is perfectly sealed against leakage and contamination.
Submerge pressurized tubes/bottles in water or use a vacuum decay leak tester.


Stress Crack Resistance
Evaluate the package's (especially caps') resistance to cracking when exposed to certain ingredients (e.g., essential oils, alcohol).
Apply stress to samples and immerse them in specific chemical agents, observing for crack formation.


Drop Test
Verify the durability of the package during transit and use.
Drop filled packages from various heights and angles onto a hard surface.


Compression Test
Ensure tubes can withstand pressure during stacking and shipping without deforming.
Apply vertical pressure to tubes to simulate warehouse stacking conditions.


Cycle Test
Assess the lifespan and reliability of pumps and valves.
A machine repeatedly actuates the pump thousands of times to check for consistent function.






Part 3: Beyond the Lab - Stability & Real-World Simulation


Light Stability Testing: Placing the filled package under intense UV light to see if the formula or package color fades. This is crucial for transparent packaging and light-sensitive formulas.



Shelf-Life Studies: Long-term real-time studies under controlled conditions (temperature & humidity) to definitively establish the product's expiration date.




Our Commitment to Your Brand's Success
At SampoX, our state-of-the-art testing laboratory is an integral part of our service. We don't just sell packaging; we deliver certainty. By partnering with us, you gain access to a rigorous quality assurance process that mitigates your risk and protects your brand's reputation before your product even hits the market.


→ Contact the SampoX Quality Team to Learn About Our Testing Services & Certifications

The Definitive Guide to Lip Balm Tubes (2026 Edition)
Production Realities, Diameter Economics, and The Science of Applicators
Author: SampoX Engineering Team
Category: Manufacturing White Paper
Reading Time: 20 Minutes (Deep Dive)


Executive Summary
The humble lip balm tube is undergoing a massive revolution. As the global "skinification" of lip care demands increasingly complex formulas—ranging from liquid oils to heavy overnight masks—the traditional wax stick mechanism is becoming obsolete. The flexible squeeze tube has emerged as the superior solution, offering better hygiene, formula compatibility, and application precision.

However, procuring this miniature packaging is fraught with invisible technical pitfalls. Why does a smaller tube often cost more? How do you fill thick formulas without expensive machinery? In this comprehensive white paper, SampoX leverages decades of manufacturing data to pull back the curtain on the lip balm tube industry.



Table of Contents

1. Redefining the Lip Balm Tube
2. The Economics of Diameter (The 13mm Paradox)
3. Applicator Diversity: Sponge, PE, & Zinc Alloy
4. Decoration Strategy: Silk Screen vs. Offset
5. Caps: The Guardian of the Applicator
6. Body Materials & The Green Challenge
7. The Startup Dilemma: Tail vs. Front Filling
8. Quality Control & Burst Testing
9. Procurement Decision Matrix


1. Redefining the Lip Balm Tube
1.1 From Passive Container to "Integrated Tool"
For decades, the lip balm market was dominated by the "twist-up stick." While iconic, the stick mechanism has a fatal limitation: it requires the formula to be solid, waxy, and stable at room temperature. This limits the inclusion of hydrating oils, active serums, or plumping agents.

The Squeeze Tube has risen to dominance because it completely decouples the packaging from the formula's viscosity. Whether your product is a runny lip oil, a semi-solid gel, or a thick repairing ointment, a tube can handle it. More importantly, the tube transforms the product into a tool. Unlike a jar (which requires a finger application) or a stick (which drags across the skin), a modern lip balm tube features an Integrated Applicator Head. The head is the tool.

1.2 Precision Micro-Manufacturing
Many procurement managers operate under a misconception: they assume that a 10ml lip balm tube is just a "shrunken version" of a 100ml cleanser tube. This is dangerous thinking. Manufacturing a 16mm diameter tube requires significantly higher precision tolerances.

In a large 50mm tube, a 0.5mm deviation in printing alignment is barely noticeable to the consumer. In a 16mm tube, that same deviation looks like a major quality defect. At SampoX, we treat lip balm tube manufacturing closer to medical device injection molding than standard cosmetic packaging.

2. The Economics of Diameter
When selecting a tube, the diameter (Ø) is the first and most critical decision. It dictates the "hand-feel," the visual presence, and surprisingly, the manufacturing cost structure.


2.1 The "13mm Paradox": Why Smaller Is More Expensive
There is a common logic in procurement: "Less plastic material equals lower unit cost." Therefore, a Ø13mm tube should naturally be cheaper than a Ø16mm tube. However, in the reality of the factory floor, this is often wrong.

At SampoX, we frequently advise clients that Ø13mm tubes carry a higher unit price due to the Scrap Rate Penalty:


Stability Issues: Ø13mm tubes are extremely slender and lightweight. On high-speed automatic filling lines (running 60-80 tubes per minute), these tubes are aerodynamically unstable. They tend to wobble in the manufacturing "pucks" (holders), leading to misaligned printing.
Sealing Defects: Because the tube is so small, the tail sealing area is tiny. Any slight movement during the heat-sealing process results in a leaked seal.

SampoX Advice: Unless your brand positioning absolutely demands a "clinical ampoule" look or an ultra-mini sample size (3ml-5ml), we strongly recommend avoiding Ø13mm. The production inefficiencies will eat into your margins.

2.2 Ø16mm & Ø19mm: The Global Gold Standard
If there is a "king" of lip balm tubes, it is the Ø16mm. It fits perfectly in a jean coin pocket or a small clutch. Because this is the most common mold size globally, production lines run at maximum efficiency with near-zero downtime. It is the optimal balance of cost and portability.

The Ø19mm is the "Premium Canvas." Brands typically switch to 19mm when the volume requirement hits 15ml (common for Lip Masks) or when they need more surface area for complex branding. The extra 3mm of width provides roughly 20% more face area, making logos significantly more legible.

2.3 Ø22mm: The Crossover Contenders
These sizes are rarely used for standard lip balms but dominate specific niches:


Ø22mm (The Hybrid): Often used for "Eye & Lip Duos." The wider body supports larger, more complex applicator heads, such as Zinc Alloy or Ceramic tips.

SampoX Engineer’s Cheat Sheet: Diameter Selection




Diameter
Ideal Volume
Characteristics
Production Cost
Best For...




Ø13mm
3ml - 5ml
Ultra-slim, Unstable
High (High Scrap)
Samples, Single-use Ampoules


Ø16mm
8ml - 12ml
Standard, Portable
Lowest (Optimal)
Daily Lip Balm, Gloss


Ø19mm
10ml - 18ml
Premium, Wide Face
Low/Medium
Lip Masks, Tinted Balms


Ø22mm
15ml - 20ml
Substantial Feel
Medium
Eye & Lip Duo, Plumpers





3. Applicator Diversity: The Core Competency
In the world of lip balms, the tube is merely the reservoir; the applicator is the product. The user experience is defined entirely by the sensation of the tip gliding across the lips. At SampoX, we categorize applicators not just by shape, but by material thermodynamics.



3.1 The Classic Slanted Tip (PE)
The "Slanted Tip" (often called the Deer Foot) commands over 80% of the market share for a reason: it is the most ergonomic shape for the lip contour. Made from Polyethylene (PE) via injection molding, it is cost-effective and durable.

However, quality varies wildly. Low-end manufacturers often leave a rough "parting line" (the seam where the mold halves meet) on the tip. This can scratch the user's lips. SampoX uses high-precision polishing molds to ensure the PE tip is seamless and glass-smooth.

3.2 TPE / Silicone: The "Soft Touch" Revolution
For sensitive skin or baby care products, rigid plastic can feel too hard. The solution is TPE (Thermoplastic Elastomer) or Silicone. By over-molding a soft TPE layer onto the neck, we create a surface that mimics the softness of a fingertip. This offers a "drag-free" glide, perfect for chapped or damaged lips.

3.3 Zinc Alloy & Ceramic: The "Cooling" Premium
This is the fastest-growing segment for luxury brands ($30+ price point).


Thermodynamics: Zinc Alloy (Zamak) has high thermal conductivity. When it touches the skin, it instantly draws heat away, creating a physical "Cooling Sensation" (Cryotherapy effect). This helps reduce puffiness and boosts circulation.
Chemical Inertness: Ceramic tips offer a similar cooling effect but with a "stone-like" smoothness. Both are ideal for high-potency serums that might react with standard plastics.

3.4 Flocked Sponge: The Gloss Specialist
For liquid lip stains, tints, or high-shine glosses, the Flocked Sponge applicator is a classic choice. The soft, velvet-like fibers hold a "reservoir" of product, allowing for a generous and even application.

Hygiene Warning: While sponges feel great, they are porous. SampoX advises clients to use robust preservative systems in their formula, as sponges retain moisture more than PE or Metal tips.

4. Decoration Strategy: Silk Screen Wins
Why Offset Printing Fails on Small Tubes
Designing for a flat box is easy. Designing for a curved, flexible cylinder with a diameter of only 16mm is an engineering challenge. Offset Printing is common for large hand cream tubes, but on a lip balm tube, it often fails. The curvature is too tight, causing offset dots to blur. Furthermore, offset ink is thin and translucent; on a colored tube base, the colors look "washed out."

The Reign of Silk Screen Printing
For SampoX lip balm tubes, Silk Screen Printing is the undisputed gold standard.


Opacity: Silk screen lays down a thick layer of ink. This means we can print a bright white text on a black tube, and it will remain crisp and purely white.
Tactile Quality: The ink layer is thick enough to be felt. This subtle "embossed" texture adds a sensory dimension that consumers associate with quality.
360° Seamlessness: Unlike labels that have a visible edge, silk screen integrates with the tube, creating a monolithic look.

5. Caps: The Guardian of the Applicator
In the lip balm category, the cap serves a singular, critical purpose: protecting the applicator head. Unlike shampoo caps which control flow, a lip balm cap must seal the applicator environment.

The Screw Cap is the only viable option for durability and seal integrity. We offer three distinct styles:


Cylindrical (Flush Fit): The sleekest look, popular in modern minimalist design.
Octagonal / Ribbed: The classic "pharmacy" look. The geometric edges provide friction, making it easier to open with greasy hands.
Double-Wall Caps: For premium lines, we place an outer acrylic shell over an inner PP thread. This adds physical weight and "glass-like" depth without changing the mechanics.

6. Body Materials & The Green Challenge
The Protection Layer: EVOH (For Sunscreens)
Lip balms with SPF (Sunscreen) often contain active chemical filters like Avobenzone or volatile essential oils like Menthol. These ingredients can migrate through standard PE, causing the tube to turn yellow, become sticky, or lose potency. To prevent this, SampoX uses 5-Layer Co-extrusion. A thin layer of EVOH (Ethylene Vinyl Alcohol) is sandwiched in the middle of the tube wall, acting as an impenetrable oxygen and chemical barrier.

PCR (Recycled Plastic): The "Black Spot" Reality
Using Post-Consumer Recycled (PCR) plastic on a tiny white tube is risky. PCR comes from waste, so it inevitably contains microscopic impurities or black specks. On a large bottle, a 0.2mm speck is invisible. On a pure white lip balm tube, it looks like dirt.

The SampoX Solution: For brands insisting on PCR, we use 3-Layer Co-extrusion. We place the PCR material in the middle layer and use pure virgin plastic for the inner and outer layers. This hides the imperfections while still allowing you to claim "30-50% Recycled Content."

7. The Startup Dilemma: Tail vs. Front Filling
For large brands (Mass Market), tubes are traditionally filled from the open tail by automated machinery and then heat-sealed. But for startups, indie brands, or beauty salons who haven't invested in a $20,000 professional tail-sealing machine, this presents a problem. Their only option is to request "Pre-sealed Tails" from the factory and fill the product through the nozzle (Front Filling).

7.1 The "Syringe Nightmare" (Viscosity vs. Orifice)
Here lies a common trap: A brand orders a standard 16mm tube with a fixed head. The nozzle orifice is typically only 1.2mm wide.


The Problem: If your lip balm formula is viscous (thick density like a mask or salve), trying to force it through a 1.2mm hole with a hand syringe is physically exhausting and incredibly slow. It creates back-pressure bubbles and slows production to a crawl.

7.2 The Solution: Removable Applicator Systems
To solve this, SampoX offers Removable Applicator Heads (Screw-on or Snap-on types) specifically for front-filling customers.


How it Works: The tube is delivered with the tail already professionally sealed by us, but the applicator head is detached (packaged separately). This leaves the full neck width (approx. 8mm-10mm) open for filling.
The Advantage: You can fill thick formulas easily through the wide neck using a standard pump or syringe. Once filled, you simply screw or snap the applicator head onto the tube. This allows small brands to achieve professional filling speeds without buying heavy machinery.

8. Quality Control & Burst Testing
Lip balms face a unique usage scenario that other cosmetics do not: they live in pockets. They are sat on, heated by body warmth, and tumbled in bags with keys. Standard QC protocols are not enough.

8.1 The "Back Pocket" Burst Test
We subject random samples from every batch to a specialized pressure test that simulates an 80kg human sitting on the tube while it is at body temperature (37°C). Most tubes fail not at the body, but at the Tail Seal.

For lip balms, we optimize the "Seal Time" and "Cooling Time" parameters to ensure the seal is fused deeply enough to withstand 20kg of direct pressure without delaminating. If a batch fails this test, it never leaves our factory.

9. Procurement Decision Matrix
To help you finalize your specifications, please use this reference table based on typical market positioning:





Brand Size / Type
Rec. Diameter
Filling Method
Recommended Configuration




Startup / Indie Brand
Ø16mm / Ø19mm
Front Fill (Syringe)
Removable Head (Wide neck for easy fill)


Mass Market Balm
Ø16mm
Tail Fill (Machine)
Fixed PE Head (Cheapest)


Lip Stain / Tint
Ø16mm
Tail Fill
Flocked Sponge + Wiper


Luxury Serum
Ø19mm
Tail Fill
Zinc Alloy / Ceramic


Medicated / Repair
Ø19mm / Ø25mm
Tail Fill
5-Layer EVOH (High Barrier)





Ready to Engineer Your Perfect Tube?
Don't risk your brand with generic packaging. Partner with the manufacturing experts who understand the science of the lip balm tube.

Request a Lip Balm Sample Kit

The "100%" Expectation
It’s the dream of every sustainable beauty brand: A cosmetic tube that is 100% plant-based, 0% fossil fuel, and fully recyclable.

You come to us and say: "I want a 100% Sugarcane Tube." We say: "No problem for the tube body. But for the cap... it's complicated."

Often, you will see specifications listing the tube body as 100% Bioplastic (Green PE), but the cap is listed as Standard PP or only 30%-50% Bio-based. Why the discrepancy?


1. The Body: Why 100% Green PE is Easy
The soft, squeezable body of a tube is made from Polyethylene (PE). Luckily, the ethanol extracted from sugarcane can be chemically converted into ethylene, which then becomes Polyethylene.

This "Green PE" (from Braskem) is chemically identical to fossil-based PE. It has the same flexibility, bounce-back, and printing surface.

Thinking of switching? You can browse our full range of [Sugarcane Tubes & Eco-Packaging] to see the different sizes available. It is a perfect 1:1 replacement for standard tubes.


2. The Cap: The "Hardness" Problem (PE vs. PP)
The cap is different. It cannot be soft. It needs to be rigid. It needs tough threads that won't strip when you tighten them.

To achieve this, caps are almost always made of Polypropylene (PP). While Green PE is mature, Green PP (Bio-PP) is much newer and scarcer. Producing rigid PP from sugarcane is chemically more complex, which creates a supply chain gap for 100% renewable caps.




3. Why Only 50%? (The Blending Reality)
If we use 100% Green PE to make a cap, it will be too soft. The threads will deform, and the flip-top hinge will feel "gummy."

To fix this, manufacturers use a Blend. We mix bio-based material with traditional fossil-based PP to add strength. Currently, pushing that bio-content past 50% often compromises the structural integrity of the cap.


4. The Solution: How to get closer to 100%?
If your brand strictness demands a higher eco-percentage, there is one workaround: Switch to a Mono-Material Tube (All PE).

Instead of a traditional PP cap, we can manufacture a cap using HDPE (High-Density Polyethylene) derived from sugarcane.



Pros: The entire package (Body + Cap) is 100% Sugarcane.



Cons: HDPE caps are more matte/waxy and less "sharp" than PP caps.




SampoX Verdict
Don't feel cheated if the cap isn't 100% sugarcane. It’s an engineering limitation, not a cost-cutting trick.



Tube Body: Go 100% Green PE.



The Cap: Accept a standard PP cap for performance, or ask us about HDPE Caps if you want a fully mono-material story.




Ready to feel the material difference?
Text and photos can only tell you so much. You need to touch the "Green PE" material to believe it feels exactly like standard plastic.

👉 [Click Here to Request Your Free Sugarcane Sample Kit] (Includes: 100% Sugarcane Tube, HDPE Cap vs. PP Cap comparison)