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Everything begins with an aluminium slug — a small, thick disc of high-purity aluminium alloy, cut to a precise weight that determines the final tube dimensions. The quality and consistency of the slug at this stage directly determines the uniformity of the finished tube. Slugs are typically produced by punching from rolled aluminium sheet or casting, and they undergo quality checks before entering the extrusion line.
The slug is placed in a die and struck by a punch under extremely high pressure — a process called impact extrusion. The force causes the aluminium to flow upward around the punch in a single stroke, forming a seamless, thin-walled tube body in one operation. This is what gives aluminium tubes their defining characteristic: a completely seamless, pinhole-free wall with no joins, welds or seams that could compromise the barrier.
The result is a tube that is simultaneously lightweight and structurally sound — able to withstand handling and distribution without the rigidity or weight of glass, and without the gas permeability of plastic.
Freshly extruded aluminium is work-hardened by the extrusion process and would crack if collapsed without further treatment. Annealing resolves this: the tubes are passed through a controlled-temperature furnace and then cooled at a defined rate. This relieves internal stress in the metal, restoring the ductility that makes collapsible tubes easy to squeeze repeatedly without splitting or cracking at the shoulder.
For rigid tubes — used for effervescent tablets, powders and solids — annealing is calibrated differently, retaining more structural stiffness while still ensuring the tube can be handled without damage.
After annealing, tubes are trimmed to their precise finished length and the shoulder and neck are formed — the tapered section that reduces from the tube body diameter down to the nozzle opening. The shoulder geometry affects both the dispensing behaviour of the finished tube and the visual profile of the product on shelf. Threads for screw caps are formed at this stage.
Before printing, the tube exterior is cleaned and a base coat is applied to ensure ink adhesion and colour accuracy. Printing is then applied using offset or screen printing, accommodating full-colour branding, regulatory text, dosage information, batch numbers, expiry dates and barcodes.
For pharmaceutical applications, the print specification must carry all required labelling under the relevant regulatory framework — including active ingredients, dosage instructions, manufacturer details and safety information — within what is often a compact surface area. BlueSky’s decoration and printing service can advise on print specifications that meet both branding and compliance requirements.
A final lacquer overcoat is typically applied to protect the print from scuffing during filling, capping and distribution.
Where the formulation requires a barrier between product and metal — for acidic, alkaline or reactive formulations — the interior of the tube is coated with a protective lacquer after the exterior print has been applied. BlueSky’s pharmaceutical-grade tubes are available with FDA-approved internal linings, which are required for many pharmaceutical and healthcare applications.
The lining prevents any interaction between the aluminium surface and the product, preserving formulation stability and ensuring the tube is compatible with a broad range of creams, ointments, gels and pharmaceutical preparations.
Tubes are fitted with closures — typically screw caps, flip-top caps or tamper-evident seals — before inspection and dispatch. At this stage, finished tubes are checked for dimensional accuracy, print registration, lining integrity and closure fit. For pharmaceutical-grade tubes, this quality process is aligned with GMP (Good Manufacturing Practice) requirements.
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Yes — and more completely than most other packaging materials. Aluminium is infinitely recyclable: it can be melted down and reformed repeatedly without any degradation in material quality. The recycled aluminium is chemically and physically identical to primary aluminium.
The recycling process works as follows:
Collection and sorting — used aluminium tubes enter the recycling stream via kerbside collections or commercial waste processing. Aluminium is separated from other materials during sorting.
Cleaning and shredding — tubes are cleaned to remove residual product and shredded into small pieces to increase surface area and speed melting.
Melting — shredded aluminium is melted in a furnace at around 660°C. Impurities and coatings are removed during this stage, producing pure molten aluminium.
Casting and remanufacture — the molten aluminium is cast into ingots or slabs, which are then rolled and processed into new products — including new aluminium tubes, completing a genuinely closed-loop cycle.
The energy saving is substantial: recycling aluminium requires approximately 95% less energy than producing it from bauxite ore. The overall aluminium recycling rate across the EU, UK, Switzerland, Norway and Iceland reached 74.6% in 2025 — one of the highest recovery rates of any packaging material.
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The case for aluminium’s recyclability has always been clear from a sustainability perspective. What has changed is that it now carries direct commercial implications for packaging specifiers in both the UK and EU.
UK Extended Producer Responsibility (EPR) — under the Producer Responsibility Obligations (Packaging and Packaging Waste) Regulations 2024, fees payable from 2025 are modulated by recyclability. Packaging made from materials with poor or costly recyclability attracts higher fees. Aluminium’s high recyclability and established UK collection infrastructure position it favourably, reducing the EPR fee burden compared with multi-layer laminates or composite materials.
EU Packaging and Packaging Waste Regulation (PPWR) — in force from February 2025 and fully applicable from August 2026, the PPWR requires all packaging placed on the EU market to meet recyclability standards and targets. Aluminium meets these criteria without material redesign. Eco-modulated EPR fees at member state level will increasingly reflect recyclability from 2030, adding further commercial weight to the material choice.
For brands selling into regulated markets — which is now effectively all markets — specifying packaging with demonstrably high recyclability is no longer just a sustainability statement. It is a cost and compliance decision.
Read more about the PPWR and EPR →
| Collapsible | Rigid | |
|---|---|---|
| Best for | Creams, gels, ointments, pastes, lotions | Tablets, effervescents, powders, solids |
| Dispensing | Squeeze; no air back-fill | Remove from container |
| Between-use protection | Excellent — no contamination or oxidation | Full barrier seal |
| Sectors | Pharmaceutical, cosmetic, dental, dermatology | Pharmaceutical, nutraceutical, supplement |
| Recyclable | Yes | Yes |
How are aluminium tubes made? Aluminium tubes are made by impact extrusion — a small aluminium slug is struck under high pressure, causing the metal to flow upward around a punch to form a seamless tube body in a single operation. The tube is then annealed for flexibility, trimmed, printed, internally lined where required, and capped.
What is an aluminium slug? An aluminium slug is a small, thick disc of high-purity aluminium alloy used as the starting material for tube manufacturing. Its weight determines the final tube wall thickness and dimensions. The slug is placed in a die and extruded under high pressure to form the tube body.
Why are aluminium tubes annealed? Annealing relieves the internal stress introduced by the extrusion process, which would otherwise make the tube too brittle to collapse without cracking. The process involves heating the tube to a controlled temperature and cooling it at a defined rate to restore ductility. Without annealing, collapsible tubes could not be squeezed repeatedly without splitting.
Do aluminium tubes need an internal lining? Not always. Many formulations are compatible with aluminium directly. However, for pharmaceutical, acidic, alkaline or reactive products, an internal lacquer lining creates a barrier between the formulation and the metal, preventing any interaction and maintaining product stability. BlueSky’s pharmaceutical-grade tubes are available with FDA-approved internal linings.
Are aluminium tubes recyclable? Yes — fully and infinitely. Aluminium can be melted down and remanufactured repeatedly without loss of quality. Recycling it uses approximately 95% less energy than primary production. The aluminium recycling rate across the EU and UK reached 74.6% in 2025, one of the highest of any packaging material.
How does aluminium tube recyclability affect UK EPR fees? Under the UK’s Extended Producer Responsibility (EPR) regulations, packaging fees from 2025 are modulated by recyclability. Aluminium’s high recyclability and established UK recycling infrastructure mean it attracts lower modulated fees compared with harder-to-recycle composite or multi-layer materials.
What printing methods are used on aluminium tubes? Offset printing and screen printing are the most common methods. Both can accommodate full-colour branding and the regulatory text required for pharmaceutical and cosmetic products. A protective lacquer overcoat is applied after printing to resist scuffing during filling and distribution.
What sizes and closures are available? Aluminium tubes are available in a range of diameters and lengths, with closures including screw caps, flip-top caps and tamper-evident seals. Contact the BlueSky sales team to discuss specific dimensions, volumes and minimum order quantities.
BlueSky Solutions supplies collapsible and rigid aluminium tubes to pharmaceutical, cosmetic, healthcare and supplement brands across the UK and EU. The team can advise on formats, lining specifications, print and decoration, EU PPWR and UK EPR considerations, and line compatibility.
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