How We Developed Kids Sunscreen Tubes for a Baby Care Brand
A baby care brand partnered with Xinfly Packaging to develop portable kids sunscreen tubes for its SPF50 mineral sunscreen line. Unlike standard sunscreen packaging, this project focused on parent-friendly use, child-safe positioning, school-bag portability, leakage prevention, mineral formula protection, and a more suitable size for daily reapplication.
After evaluating the usage scenario, formula type, retail channel, and transportation risk, our engineers recommended a 35mm diameter 60ml EVOH sunscreen tube with a flip-top cap. This structure was designed to be easier for parents to carry, easier to squeeze, and more practical than larger 100ml sunscreen tubes for children’s outdoor activities.
Project Background
The customer was preparing to launch a children’s sunscreen collection for baby care retailers, pharmacies, e-commerce channels, and family outdoor travel products. The product line included kids sunscreen SPF50, baby mineral sunscreen lotion, and portable sunscreen products for school bags, beach bags, and travel kits.
Before working with Xinfly Packaging, the customer considered using a standard 100ml sunscreen tube. However, after reviewing the actual consumer scenario, our engineering team found that a 100ml tube was not the best fit for children’s sunscreen. Parents usually need a smaller and more portable sunscreen format for school, travel, sports, camping, and daily outdoor reapplication.
Based on Xinfly’s experience in kids sunscreen tubes, mineral sunscreen tubes, EVOH sunscreen tubes, and SPF sunscreen tube packaging, we recommended a more targeted 35mm diameter 60ml tube structure.
Customer Pain Points Before Development
Oversized Sunscreen Tubes Were Not Kid-Friendly
- The customer initially considered a 100ml tube, but it felt too large for school bags and travel kits.
- Parents needed packaging that was easy to carry for daycare, summer camp, beach trips, and outdoor sports.
- The brand wanted a tube that looked suitable for children rather than adult family sunscreen.
Leakage Risk in Bags and Hot Weather
- Kids sunscreen is often stored in backpacks, beach bags, stroller organizers, and cars.
- High temperature and repeated movement increase leakage risk during summer use.
- The customer needed a secure closure and stable tube structure for real family usage scenarios.
Mineral SPF Formula Needed Protection
- The sunscreen formula used a mineral SPF system designed for children’s sensitive skin.
- The customer wanted better packaging protection than a simple mono-layer tube.
- SPF stability, shelf life, and formula compatibility were important for retailer confidence.
Factory Engineer’s Recommendation: 35mm Diameter and 60ml Capacity
From a factory engineering perspective, kids sunscreen packaging should be designed around real parent behavior. Parents do not always carry a full-size sunscreen bottle or 100ml tube for short outdoor activities. They often need a compact sunscreen tube that fits into a school bag, mom bag, beach bag, stroller pocket, or travel kit.
Based on 15+ years of cosmetic tube manufacturing experience, our engineers recommended a 35mm diameter 60ml tube. This format provides a better balance between portability, squeeze comfort, product volume, shelf appearance, and shipping efficiency. Compared with a 50mm 100ml tube, the 35mm 60ml format feels more child-friendly and is easier for parents to carry for daily reapplication.
We also recommended a 5-layer co-extruded structure with an EVOH barrier layer to support SPF formula protection. For future sustainability upgrades, the same concept can also be evaluated with PCR sunscreen tubes, recyclable cosmetic tubes, or eco-friendly sunscreen tubes.
Why We Recommended 35mm Instead of 30mm
Better Tube Proportion
A 30mm tube can become too long when filled to 60ml, which may reduce shelf appearance and make the tube less stable when standing upright. The 35mm diameter creates a better visual balance for children’s sunscreen packaging.
Improved Squeezing Comfort
A 35mm tube provides a wider grip area and smoother squeezing experience. This is important because parents often apply sunscreen quickly while managing children outdoors.
More Stable Production
The 35mm diameter supports more efficient filling, more stable sealing, and better tube recovery than a narrow long tube. This helps reduce production risk and supports repeat order consistency.
Why We Recommended 60ml Instead of 100ml
More Portable for Parents
A 60ml tube is easier to place in school bags, travel kits, beach bags, and stroller organizers. It is especially suitable for reapplication during school, sports, and outdoor activities.
Better for Trial and Retail Sets
The 60ml size works well for starter kits, family travel packs, seasonal SPF promotions, and e-commerce bundles where portability and lower entry price matter.
Lower Shipping Pressure
Compared with larger 100ml sunscreen tubes, 60ml tubes reduce unit weight and shipping space, making them more friendly for online sales, pharmacy retail, and international distribution.
Final Packaging Specifications
The final kids sunscreen tube solution was developed around portability, sunscreen stability, safe family use, leakage prevention, and clean baby care branding. The 35mm diameter 60ml EVOH tube gave the customer a practical packaging structure for children’s SPF products.
Services Provided by Xinfly Packaging
Unlike standard sunscreen tube manufacturing projects, this kids sunscreen packaging project required additional consideration for family usage behavior, portability, leakage prevention, formula stability, and future sustainability upgrades. Xinfly Packaging provided complete engineering support throughout the development process.
Packaging Engineering
- Formula compatibility evaluation
- Tube diameter optimization
- EVOH barrier recommendation
- Cap structure selection
- Leakage prevention testing
- Transportation simulation
Design & Decoration Support
- Kids-friendly packaging design review
- Matte finish recommendation
- Pantone color matching
- Cartoon artwork adaptation
- Offset printing optimization
- Brand consistency support
Production & Supply Chain Support
- Custom sampling
- Mass production management
- Quality inspection
- Export packaging support
- Repeat order consistency control
- Global delivery coordination
How We Solved the Customer's Biggest Challenges
Portable for Parents
Instead of using a bulky 100ml tube, we developed a 60ml format that easily fits into school bags, diaper bags, beach bags, and travel kits. Parents can carry the product everywhere children need SPF protection.
Improved SPF Stability
The sunscreen formula contained mineral UV filters and required stronger protection than ordinary personal care products. Our engineers recommended an EVOH barrier structure to improve product stability and reduce oxygen transmission.
Reduced Leakage Risk
A secure flip-top cap combined with optimized shoulder and sealing design helped reduce leakage risks during transportation, travel, and everyday use.
Safety Considerations for Kids Sunscreen Packaging
Children's sunscreen packaging should not be treated the same as standard adult sunscreen packaging. Parents pay close attention to product safety, convenience, portability, and packaging quality.
BPA-Free Materials
PE tube structures can be manufactured using high-quality cosmetic-grade materials suitable for children's personal care products.
Comfortable Dispensing
The 35mm diameter provides comfortable squeezing force, making sunscreen application easier for parents.
Reliable Closure
A flip-top cap helps prevent accidental opening and leakage in school bags and travel kits.
Relevant Packaging Solutions for Children's SPF Products
Kids Sunscreen Tubes
Designed specifically for children's sunscreen products. Learn more about Kids Sunscreen Tubes.
Mineral Sunscreen Tubes
Suitable for zinc oxide and titanium dioxide sunscreen formulas. View Mineral Sunscreen Tubes.
PCR Sunscreen Tubes
Support sustainability goals with PCR Sunscreen Tubes.
Reef-Safe Sunscreen Packaging
Explore solutions for modern environmentally conscious sunscreen brands through Reef Safe Sunscreen Tubes.
About Xinfly Packaging
With more than 15 years of manufacturing experience, Xinfly Packaging specializes in custom sunscreen tubes, skincare tubes, personal care tubes, and cosmetic packaging solutions. We help global brands select suitable tube structures based on formula type, application scenario, sustainability goals, filling requirements, and budget targets.
For sunscreen projects, our engineering team frequently works with EVOH sunscreen tubes, PCR sunscreen tubes, SPF sunscreen tubes, and travel-size sunscreen packaging.
Development Process
Project Results
Client Feedback
"We initially planned to use a standard 100ml sunscreen tube. Xinfly Packaging's engineering team helped us understand how parents actually use children's sunscreen products. The recommended 60ml EVOH tube was easier to carry, easier to use, and more aligned with our target market."
— Product Development Manager, Baby Care Brand
Frequently Asked Questions
Why use EVOH tubes for kids sunscreen?
EVOH barrier layers provide improved protection for SPF formulas and help maintain product stability.
Can kids sunscreen tubes use PCR material?
Yes. PCR PE structures are available for brands with sustainability goals.
Why choose 60ml instead of 100ml?
60ml is easier to carry in school bags, travel kits, and beach bags while remaining practical for reapplication.
Why is 35mm diameter recommended?
35mm offers better balance, improved squeezing comfort, and more attractive proportions for 60ml sunscreen tubes.
What cap type is recommended?
Flip-top caps are typically preferred because they are easy for parents to use and help reduce cap loss.
Can you support mineral sunscreen formulas?
Yes. We frequently work with zinc oxide and titanium dioxide sunscreen packaging projects.
Can the tubes be BPA-free?
Yes. Cosmetic-grade materials can be selected to meet product requirements.
Can you print cartoon designs?
Yes. Offset printing and decorative options support children's branding and packaging graphics.
Can you provide samples?
Yes. Stock samples and custom samples are available.
Do you export to North America?
Yes. We regularly supply packaging solutions to customers in the USA and Canada.
Can you support reef-safe sunscreen brands?
Yes. We support packaging projects for reef-safe sunscreen products.
What information is needed for a quote?
Please provide capacity, tube diameter, material preference, artwork, quantity, and target market.
Developing a Kids Sunscreen Product?
Whether you're launching a baby sunscreen, kids sunscreen SPF50, reef-safe sunscreen, or mineral sunscreen product line, Xinfly Packaging can help you create safe, portable, and professionally engineered sunscreen tube packaging solutions.