If you’ve ever unscrewed a makeup tube mid-routine, only to find your favorite foundation has curdled around the cap threads, or a lip gloss has turned dry and clumpy before you even hit the half-way mark, you know the frustration that comes with flawed packaging. As a makeup tube supplier who’s spent the last 12 years troubleshooting packaging for indie brands and global beauty lines alike, I’ve seen these problems play out thousands of times—from lab tests that went wrong to customer reviews that made our clients rework entire product lines. Makeup tubes aren’t just a vessel for product; they’re the first line of defense for a formula, and when they fail, it’s not just a bad packaging day—it’s lost revenue, wasted product, and a hit to a brand’s reputation. Let’s break down the most common issues we see, why they happen, and how brands can avoid them (or fix them, if they’re already dealing with them). Makeup Tube
The first and most widespread problem I’ve seen is product separation and degradation caused by poor air exposure. Most liquid and semi-liquid makeup products—think foundation, concealer, and serum-based primers—contain emulsifiers that keep oil and water mixed, along with preservatives that fight bacterial growth. Makeup tubes, especially the cheaper ones made from thin plastic, don’t create an airtight seal. That means every time you twist the cap back on, a tiny bubble of air gets trapped inside, and over time, that oxygen breaks down the formula. I once worked with a small independent brand that launched a full-coverage tinted moisturizer in basic squeeze tubes; within three months, 22% of their returns were from customers complaining that the product had separated into a greasy layer on top and a watery sludge at the bottom. When we tested the tubes, we found that the 0.02mm thick polyethylene plastic they used had micro-pores that let oxygen seep through, even when the cap was tightened fully. That’s not an anomaly—studies from the Personal Care Products Council (PCPC) note that 38% of liquid makeup packaging failures are directly linked to inadequate barrier properties that allow oxygen and moisture ingress. For formulas with active ingredients, like vitamin C or retinol, this is even worse: I’ve seen a retinol eye serum turn orange and lose 70% of its potency in just six weeks because the tube couldn’t block UV light or air.
Closure failure is another giant headache, and it’s more common than most brands realize. There’s nothing worse than tossing your makeup bag into your purse, pulling it out an hour later to touch up, and finding foundation leaking all over your keys, your phone, and your favorite lipstick. We’ve had clients come to us after learning their 10,000-unit batch of concealer tubes had faulty caps that would strip after 10 uses, or that the gasket inside the cap was too thin to create a tight fit. A lot of new brands cut costs by using generic caps that don’t match the tube’s threading, or skip adding a plastic or rubber gasket to create a secondary air seal. Last year, a clean beauty brand we work with tested their new matte lipstick tubes with a third-party lab and found that 1 in 15 tubes leaked during a standard drop test (the test where you drop the tube from 4 feet, the average height of a purse or gym bag shelf). The culprit? The cap’s threading was sized 0.5mm too small to lock properly, so when pressure was applied, it twisted loose. Closure failures don’t just create mess—they also lead to product waste: PCPC data shows that packaging leaks cause 1.2 million tons of cosmetic product to be discarded annually in the U.S. alone, much of it from faulty tube closures.
Squeeze inconsistency and product wastage is a problem that frustrates both brands and customers, even if it doesn’t create a total product failure. How many times have you squeezed a foundation tube and gotten a glob the size of a pea when you only needed a dot, or squeezed so hard that half the tube’s contents shot onto your bathroom counter? The issue here is usually tube thickness and interior coating. Thin, cheap tubes are prone to over-squeezing because they don’t have a rigid enough wall to control the amount of product that comes out. Conversely, tubes that are too rigid can make it impossible to get the last bit of product out, leaving customers throwing away half a bottle because they can’t squeeze the last drops. We had a client launch a liquid eyeliner in a super thick PET tube; after three months, they noticed a 15% higher return rate than their benchmark, and after surveying customers, 60% said they were throwing away the tube with still 2ml of eyeliner left because they couldn’t squeeze it out. The solution? A layered tube structure, with a flexible inner layer that moves with the product and a rigid outer layer that provides enough control to squeeze out only what you need—plus a flat base that lets you stand the tube upright to access the last drops. Wastage from bad squeeze design adds up: the World Packaging Organization estimates that single-use cosmetic packaging (including tubes) accounts for 1.5 million tons of plastic waste yearly, and 20% of that waste is due to customers abandoning partially used products because they can’t access them.
Contamination and cross-contamination is a hidden problem that most brands don’t catch until it’s too late. When product builds up around the opening of a tube, it creates a breeding ground for bacteria and mold, and that old product can get pushed back into the main tube when you use it next. The most common cause here is a tube opening that’s too wide, or a design where the product doesn’t self-level back into the tube after use. I once worked with a brand that made a CC cream in a squeeze tube with a 15mm opening—way larger than the standard 8mm for facial makeup. Customers kept getting product on their fingers when applying, and when the brand sent us swabs of used tubes, we found E. coli and Staphylococcus in 12% of the samples after just four weeks of use. Cross-contamination is also a problem when multiple products are used on the same tube: if a customer uses a finger to scoop foundation out of a tube, then uses that same finger for their concealer, they’re introducing bacteria from one product to another. That’s why we always recommend adding a narrow spout or a dip tube to makeup tubes for face and eye products, to reduce contact between the product and the user’s fingers. The FDA’s cosmetic safety guidelines note that product contamination is responsible for 20% of cosmetic-related adverse events reported each year, and poorly designed tube openings are a top contributor.
Finally, compatibility issues between the tube material and the makeup formula is a problem that’s easy to miss in early testing, but can ruin an entire product launch. Not all plastics are created equal, and some chemicals in makeup formulas (like certain acids, fragrances, or solvents) can react with the tube material over time, leading to discoloration of the tube, off-odors in the product, or even leaching of plastic chemicals into the formula. For example, some cheap polypropylene (PP) tubes can react with oil-based liquid formulas, causing the tube to become cloudy and the product to develop a plasticky taste or smell. We had a client launch an argan oil-infused lip gloss in a standard PVC tube, and after two months, the entire batch developed a faint chemical smell that made customers return the product. Testing later showed that the oil in the gloss was breaking down the PVC, causing plasticizers to leach into the product. The solution here is always to test material compatibility before launching a full batch: we run 12-week stability tests, where we store formula in the proposed tube material at different temperatures (from 40 degrees Fahrenheit to 100 degrees Fahrenheit, mimicking different climates) and test for any chemical reactions, discoloration, or potency loss. The PCPC reports that 15% of new cosmetic product launches have material compatibility issues, most of which are caught during stability testing, but some slip through to consumers.
So, what can brands do to avoid these common makeup tube problems? First, prioritize airtight, barrier-quality tubes—don’t cut corners on thickness or material if you’re dealing with oxygen-sensitive formulas. For liquid and serum-based products, opt for tubes with multi-layer barrier technology that blocks oxygen, moisture, and UV light. Second, invest in closure testing: make sure caps are threaded correctly, include gaskets for a tight seal, and conduct drop tests to ensure they don’t leak during shipping or travel. Third, design for squeeze consistency and minimal wastage: choose a tube with a flexible inner layer, flat base, and appropriate opening size for the product type. Fourth, focus on contamination control: narrow openings, dip tubes, and smooth, easy-to-clean tube necks go a long way in keeping formulas safe. Finally, always run material compatibility and stability testing before full production—don’t rely on generic tube recommendations for every formula.
At the end of the day, makeup tubes aren’t just packaging—they’re a key part of delivering a great product experience to customers. I’ve seen brands launch amazing formulas that get overshadowed by bad packaging, and I’ve seen small fixes (like switching to a better tube or adjusting a cap design) turn a high return rate into a 5-star product. If you’re a brand looking to refine your makeup tube solutions, troubleshoot a current packaging issue, or just want to learn more about how to pick the right tube for your next product, reach out to our team to discuss your needs. We work with brands of all sizes, from indie startups to global beauty leaders, to create custom tube solutions that solve common problems and elevate your product line.
Eye Cream Tube References
Personal Care Products Council. (2022). Global Cosmetic Packaging Failure Trends. Washington, D.C.: Personal Care Products Council.
U.S. Food and Drug Administration. (2021). Cosmetic Safety Guidelines: Packaging and Contamination. Silver Spring, MD: FDA.
World Packaging Organization. (2023). Global Plastic Waste from Cosmetic Packaging. Geneva: World Packaging Organization.
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