PBL conversion for laminate tube production

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The growing demand for recyclable laminate tubes

Sustainability is transforming the tube packaging market. Global brands and regulators are increasingly pushing for recyclable packaging solutions, accelerating the shift from Aluminum Barrier Laminate (ABL) tubes to Plastic Barrier Laminate (PBL) tubes.

PBL tubes offer strong barrier protection while using an all-plastic structure compatible with standard HDPE recycling streams. This makes them an attractive solution for brands looking to reduce aluminum use and improve recyclability.

For tube producers, the ability to manufacture PBL tubes is becoming an important competitive advantage.

  • Smallest recyclable Saesa® laminated tube to date, with Ø12.7 mm.
  • Flexography printed.
  • Ultra-thin PBL laminate.
  • Fully recyclable.

Why transition to PBL tube production?

Converting your laminate tube line to PBL production allows you to respond to changing market expectations while protecting your existing equipment investment.

Key benefits include:

  • Meet brand sustainability requirements: Many global cosmetics, personal care, and pharmaceutical brands are moving toward recyclable laminate structures.
  • Prepare for future regulations: Packaging regulations increasingly expect recyclable and mono-material solutions.
  • Expand your product portfolio: Produce both ABL and PBL tubes on the same equipment.
  • Win new business opportunities: Offer sustainable tube packaging to current and new customers.

Upgrade your existing machine instead of replacing it

With Aisa’s PBL conversion upgrade, your existing laminate tube machinery can be adapted to produce PBL tubes alongside traditional ABL tubes.

This approach allows you to:

  • Avoid the cost of purchasing a new machine
  • Extend the lifetime of your existing equipment
  • Maintain production flexibility between ABL and PBL formats

upgrade machine

Our engineers evaluate your machine configuration and implement the necessary upgrades while ensuring minimal disruption to your production schedule.

Proven performance on existing Aisa machines

Aisa machines are designed for long-term performance and adaptability.

For example, in 2020 we successfully upgraded a SAESA®500Line installed more than 15 years earlier. After the upgrade, the machine was able to produce high-quality recyclable PBL tubes at speeds comparable to ABL production (up to 500 tubes per minute).

This demonstrates how Aisa upgrade solutions allow customers to keep their equipment competitive even after many years of operation.

Supported by Aisa technical expertise

Our service teams support you throughout the conversion process by providing:

  • Technical assessments of your equipment
  • Installation and commissioning of upgrade modules
  • Operator training for PBL processing
  • Ongoing technical support and process optimization after the upgrade

This ensures a smooth transition and reliable production performance.

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