Blister packaging is essential for packaging tablets and capsules in the pharmaceutical industry. It ensures product protection, helps maintain integrity, and provides tamper-evidence. Below, we explain the main types of blister packaging, the materials used, and how to select the best option for your pharmaceutical products.
Types of Blister Packaging
1. Face-Seal Blister
This common type involves molding a plastic blister to fit the product and heat-sealing it to a cardboard backing. It is widely used for lightweight pharmaceutical products such as over-the-counter medications and tablets.
Image source:VisiPak
2. Full-Face Seal Blister
In this design, the plastic blister extends over the entire face of the packaging card, offering greater protection and structural integrity. It’s ideal for products that require more robust handling or need extra protection during transit.
Image source:VisiPak
3. Trapped Blister
The blister is placed between two layers of cardboard, reducing plastic use and providing a premium look for branding purposes. This eco-friendly packaging is often used for high-end pharmaceutical products or those requiring a more aesthetic presentation.
Image source:VisiPak
4. Alu-Alu (Cold-Formed Aluminum) Blister
This packaging uses aluminum foil on both sides, providing the highest level of protection against light, moisture, and oxygen. It’s best suited for highly sensitive medications, such as those that are light- or moisture-sensitive.
5. Clamshell Packaging
A hinged plastic container that encloses the product entirely, providing excellent protection. While it’s commonly used for high-value products, it’s less frequent in pharmaceuticals due to higher production costs.
Image source:VisiPak
Plastic Materials Used in Blister Packaging
Blister packaging uses several types of plastic materials, each suited to different applications:
1. PVC (Polyvinyl Chloride)
Applications: PVC is the most widely used material for pharmaceutical blister packaging. It is popular for packaging tablets and capsules due to its cost-effectiveness and clarity.
Properties: PVC provides decent protection against moisture and is easy to form, making it ideal for mass-produced medications. However, it has lower resistance to oxygen and light.
2. PET (Polyethylene Terephthalate)
Applications: PET is commonly used for packaging consumer goods and electronics, though it's less common in pharmaceuticals.
Properties: PET is stronger and more environmentally friendly than PVC. It’s fully recyclable, making it a good option for companies focused on sustainability. However, it has higher permeability to moisture, limiting its application in sensitive pharmaceutical products.
3. PP (Polypropylene)
Applications: Found in heat-resistant packaging, especially for medical devices or pharmaceuticals that need sterilization.
Properties: PP offers higher heat resistance than PVC and PET, making it ideal for products that need to withstand high temperatures. However, it is less transparent than other plastics, which can reduce product visibility.
4. PS (Polystyrene)
Applications: Used for lightweight pharmaceutical and medical products.
Properties: PS is affordable and lightweight, but its impact resistance and barrier properties are not as strong as other plastics, making it less suitable for high-end pharmaceutical products.
5. Aluminum Foil
Applications: Primarily used in cold-formed blister packaging for products that are highly sensitive to environmental factors like moisture or light.
Properties: Aluminum provides the best barrier protection against external elements, making it ideal for packaging sensitive drugs. However, it can be more costly and results in bulkier packaging.
6. Cyclic Olefin Polymer (COP)
Applications: Used in high-end pharmaceutical packaging, including pre-filled syringes.
Properties: COP offers excellent chemical resistance and clarity, with better barrier properties than traditional plastics, though it is more expensive.
Choosing the Right Blister Packaging
When selecting blister packaging, consider the following:
Product Sensitivity: If the product is highly sensitive to moisture or light, Alu-Alu (cold-formed aluminum) blister packaging is ideal due to its superior protection. For less sensitive products, PVC may suffice.
Cost: PVC is the most affordable option for most pharmaceutical applications, but trapped blister or PET packaging may be preferable if sustainability is a concern.
Heat Resistance: For products that need to undergo sterilization, PP is a better choice due to its higher heat tolerance.
Blister packaging continues to be a go-to solution for pharmaceutical packaging, offering a balance of product protection, visibility, and tamper-evidence. Manufacturers must carefully evaluate the sensitivity of their products and the packaging's sustainability to select the best solution for their needs.
For a more detailed look at how blister packaging machines can benefit your pharmaceutical production, explore the options offered by LTPM China, a leader in pharmaceutical machinery and blister packaging solutions.