Contact Sales on +44 (0)1472 240940

Berlin Packaging expands its presence in EMEA with the acquisition of BlueSky.

Dip tube cutting
& cap wadding 

Precision finishing that makes sure your pump, sprayer or closure fits your exact bottle – not just a standard one.

Treatment pumps, lotion pumps, trigger sprays and atomisers are supplied with dip tubes in standard lengths, but bottle heights vary – particularly with bespoke or less common formats.

Berlin Packaging | BlueSky trims dip tubes to the exact length your bottle needs, and fits cap liners to your chosen closure, so your finished pack draws product properly and seals correctly from the first run.

Why this matters 

  • A dip tube that’s too long can kink, drag on the base, 
or restrict flow through the pump or sprayer.
  • A dip tube that’s too short won’t draw product from the base of the bottle, leaving usable product behind and affecting your quoted fill yield.

This is especially relevant when moving to a bespoke or 
custom-moulded bottle height, switching bottle suppliers or formats, or working with higher-value formulations where residual waste matters.

Custom Moulding & Tooling and dip tube trimming often go hand in hand – if you’re developing a bespoke bottle shape, it’s worth raising your pump or sprayer choice at the same time so the dip tube length is right from the first sample.

What we do

Dip Tube Trimming

Treatment pumps, lotion pumps, trigger sprays and atomiser sprayers are stocked with dip tubes in various common lengths — but if none suit your chosen bottle, we trim them to match, saving you the cost and lead time of a non-standard part.

Applies to: Treatment pumps, lotion pumps, trigger sprays, atomiser sprayers
Liner types: 6 semi-automatic machines
MOQ: 1,000 units
Lead time: 5 days, subject to quantity

Cap Wadding

Cutting, insertion and fixing of liners - EPE, Induction Heat Seal (IHS) and Pressure Sensitive (PS) - into any size cap of your choice, so your closure matches your product and filling process

Applies to: Any size cap
Liner types: EPE (Expanded Polyethylene), IHS (Induction Heat Seal), PS (Pressure Sensitive)
MOQ: 1,000 units
Lead time: 5 days, subject to quantity

The right liner affects how a pack seals and performs in transit and on shelf - talk to us about your product and filling process and we'll recommend the right fit.

Getting it right first time

A pump that doesn’t dispense properly, or a cap that fails to seal and protect the contents, can mean delays to your product development timeline.

Dip tube cutting and cap wadding are quick checks worth building into your development process. Where required, Berlin Packaging | BlueSky provides these as a standard 
part of matching pumps, sprayers or closures to your bottle or container.

Frequently Asked
Questions

What is dip tube cutting?
Yes — if you’re developing a bespoke bottle through our Custom Moulding & Tooling service, it’s worth confirming your pump or sprayer choice at the same time, so the dip tube length is correct from the first sample rather than adjusted later.

If your bottle is a bespoke or less common height, or you’re pairing a pump/sprayer with a bottle it wasn’t originally stocked against, it’s worth checking. A dip tube that’s the wrong length can restrict flow or leave product undrawn at the base.

EPE (Expanded Polyethylene), IHS (Induction Heat Seal) and PS (Pressure Sensitive) are different liner materials and fixing methods used inside a closure. The right choice depends on your product, your filling process and your closure type — talk to us about your specific requirement.

Both services run to a minimum order quantity of 1,000 units, with a lead time of around 5 days, subject to quantity.

Yes — if you’re developing a bespoke bottle through our Custom Moulding & Tooling service, it’s worth confirming your pump or sprayer choice at the same time, so the dip tube length is correct from the first sample rather than adjusted later.

Check your dip tube or cap wadding requirement 

Tell us your bottle, pump/sprayer or cap, and volumes, and we’ll confirm fit, MOQ and lead time.

01472 240940
sales@blueskysolutionsuk.com 

Request Sample Pack

Please note: Free shipping is available to mainland UK addresses only. We review all requests and will reach out to you if we need any additional information before organising the shipment. Thank you for your interest!

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Reminder, if ordering a sample of a bottle, don't forget to order samples of the closures you need and vice versa.

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If there is anything you wish to discuss urgently, please contact us on +44 (0)1472 240940.