Blister packaging is extensively utilized in the pharmaceutical sector to protect and dispense medications. Traditionally, these packages are composed of polyvinyl chloride (PVC) and aluminum foil, materials that pose significant challenges to recycling efforts due to their composite nature. The push towards sustainability has led to the exploration of alternative materials and technologies aimed at improving the recyclability of blister packaging.
1. Advancements in Recyclable Blister Packaging:
(1)Adoption of Mono-Material Solutions:
Polyethylene Terephthalate (PET): PET is renowned for its clarity, strength, and recyclability. Companies like Klöckner Pentaplast have developed kpNext™, a recyclable PET blister film compatible with existing pharmaceutical manufacturing equipment. This innovation facilitates easier recycling processes.
Polypropylene (PP): PP offers excellent chemical resistance and low moisture absorption. SÜDPACK Medica's PharmaGuard® is a PP-based recyclable blister concept that meets the stringent requirements of pharmaceutical packaging, providing an effective barrier and processability.
(2)Development of Recyclable Lidding Materials:
Advancements have been made in creating lidding films that are also recyclable, ensuring the entire blister package can be processed within the same recycling stream. For instance, Liveo Research AG introduced Blis|Lid MA, a PET lidding developed in collaboration with adapa Denmark Slagelse A/S, designed for easy separation and recyclability.
(3)Technological Innovations in Design:
Designing blister packs with recyclability in mind includes features like easy-separation designs, allowing consumers to effortlessly separate different materials, thereby facilitating recycling. Additionally, the use of heat-sealable coatings and peelable films enables cleaner separation of materials without compromising product integrity.
2. Case Studies:
Amcor's AmSky™ Blister System: Amcor developed the AmSky™ blister system, a recyclable solution made entirely from high-density polyethylene (HDPE). This system eliminates PVC, enhancing recyclability and reducing the carbon footprint by up to 70% compared to traditional blister packaging.
Image Source:Amcor
Liveo Research's A-PET Blister Solution: Liveo Research AG expanded its product portfolio with a complete A-PET pharma blister solution, consisting of Blis|Form MA, a halogen-free A-PET film, and Blis|Lid MA, a PET lidding. This mono-material solution is designed for recyclability in the A-PET stream and offers a user-friendly, easy push-through experience comparable to aluminum lidding.
Image Source:Liveo Research
3. Challenges and Considerations:
Material Compatibility: Ensuring that alternative materials like PET and PP meet the pharmaceutical industry's requirements for barrier properties, chemical resistance, and patient safety is crucial.
Regulatory Compliance: Packaging materials must comply with stringent regulatory standards to ensure product safety and efficacy. For instance, the European Chemicals Agency (ECHA) has evaluated the safety of PVC in medical applications, confirming its safe production and use in Europe.
Infrastructure for Recycling: The effectiveness of recycling programs depends on the availability of appropriate recycling infrastructure. Materials like PET are widely recycled; however, ensuring that blister packs are correctly sorted and processed remains a challenge.
4. Future Directions:
The pharmaceutical industry is moving towards sustainable packaging solutions by adopting recyclable materials and innovative designs. Collaboration among material scientists, packaging engineers, and regulatory bodies is essential to develop standards and technologies that enhance the recyclability of blister packaging. Continued research and development aim to balance the need for product protection with environmental sustainability.
Advancements in materials such as PET and PP, along with innovative design technologies, are paving the way for more recyclable blister packaging solutions in the pharmaceutical industry. Overcoming regulatory and technical challenges through continued innovation and collaboration will be key to achieving sustainability goals.
Explore our range of sustainable blister packaging solutions tailored to meet your pharmaceutical needs. Contact us today to learn how we can assist you in achieving your sustainability objectives.