The ABL Controversy: How Long Can Aluminum Barrier Tubes Survive?

Introduction

For 30 years, the ABL (Aluminum Barrier Laminate) tube was the undisputed king of the industry. It was cheap. It was strong. It blocked 100% of oxygen. If you bought a toothpaste or a hair dye in 2010, it was ABL.

But in 2026, the mood has shifted. With major retailers introducing "Clean Packaging" guidelines and governments imposing plastic taxes, ABL is suddenly the villain. The question is no longer if you should switch, but when.

1. The Problem: The "Unseparable Sandwich"

Why do recyclers hate ABL? Because it is a multi-material nightmare.

The Structure: Plastic + Glue + Aluminum Foil + Glue + Plastic. To a recycling machine, this is confusing.

• It looks like plastic.

• But when melted, the aluminum turns into ash and contaminants, ruining the batch of recycled plastic.

• The Result: Most ABL tubes are sorted out and sent straight to the landfill or incinerator. They are technically "recyclable" in a lab, but not in the real world.

2. The "Toothpaste Revolution"

The biggest signal came from the giants. When Colgate and Unilever spent millions developing Mono-material HDPE tubes to replace ABL, they set a new global standard. They proved that you don't need metal to keep toothpaste fresh.

The Market Reality: If a $3 toothpaste can afford to switch to eco-friendly Mono-material, consumers will start asking: "Why is my $50 luxury cream still in a non-recyclable metal tube?"

3. Is ABL Dead? Not Yet. (The Exceptions)

Before you panic, let’s be fair. ABL still has a fortress where it is safe—for now.

• Pharmaceuticals: Medicated ointments often require strict FDA stability data that only aluminum can provide.

• Aggressive Chemicals: Hair dyes, bleaching creams, and solvent-based glues will eat through plastic. They need metal.

• The "Metal Feel" Lovers: Some brands simply love the "Dead Fold" (the way the tube stays squeezed). It feels vintage and clinical.

But for 90% of Skincare (Lotions, Cleansers, Sunscreens)? You do not need ABL anymore.

4. The Replacement: High-Barrier PBL (EVOH)

The technology has caught up. EVOH (Ethylene Vinyl Alcohol) is the transparent plastic resin that killed the aluminum star.

• Protection: A 5-layer EVOH tube offers oxygen barriers that are sufficient for Vitamin C and Retinol.

• Recycling: Because EVOH is a polymer, it can be co-extruded with PE. The entire tube can be melted down and reborn.

• Aesthetics: No more ugly wrinkles. Your branding stays sharp.

Conclusion: Plan Your Exit

If you are launching a new product today, choosing ABL is a risk. You are betting against the future.

At SampoX, we still manufacture high-quality ABL for our pharma clients. But for our beauty partners, our advice is clear: Skip the metal. Go Mono-material.

Want to test if EVOH is strong enough for your formula? [Request a Stability Test Kit]