Historically, pharmaceutical blisters have been difficult to recycle – until now. Rotorprint has developed a recyclable and reusable blister composed of 100% PET and a high barrier – making it possible to reduce waste. 

What are the structures of the pharmaceutical blister?

The pharmaceutical industry is renowned for its complex blister packaging solutions, composed of a base and a film forming.

 The composition of the materials composing the base of the product have experienced changes over time; however, aluminum is the sole material employed to construct the lid.

The base material for manufacturing pharmaceutical blisters typically consists of either polyvinyl chloride (PVC) or polyvinylidene chloride (PVdC). The material selection is based on the required barrier qualities necessary to preserve the integrity of the pharmaceutical product.

The base determines the barrier qualities of the blister

The pharmaceutical blister complex comprises two materials: aluminum, with a barrier to oxygen (OTR) and water vapor (WTR), both equal to zero, and the base material. The barrier qualities of a 20 aluminum film are consistently superior to those of any base material other than aluminum, making it the primary determinant for the overall barrier qualities of the pharmaceutical blister.

Polyvinyl chloride (PVC) containers typically exhibit resistance to oxygen below 15, while the resistance to water vapor is usually lower than 3.2.

The toxicity of PVC

In the late 1990s, multinational corporations like IKEA and Lego took a stance against using PVC in their products.

The high chlorine content of polyvinyl chloride (PVC) has led to its restriction in numerous countries due to the toxic hydrogen chloride vapors it produces when burned, which can be detrimental to public health.

Pharmaceutical blister: from PVC to PET

Given the hazardous effects of PVC and the increasing regulations upon its use, brands are turning to PET as an alternative for the base of pharmaceutical blisters. Rotor Print specializes in providing weldable aluminum for this purpose.

The transition from PVC to PET in packaging is causing shifts in barrier levels, with the oxygen barrier now set at less than 17 and the water vapor barrier at less than 3.

High barrier 100% PET blister

Rotor Print has taken a further step in the packaging industry by developing a high-grade PET blister that provides an equal barrier to the traditional aluminum lid. This PET film offers optimal protection for product stability and shelf life.

Recyclable pharmaceutical blisters with the same protective barriers as traditional PVC and aluminum compounding have been successfully achieved.

Recyclable pharmaceutical blister

Blisters cannot be recycled due to the difficulty of separating the aluminum material from its plastic base.

We have developed a mono blister with PET material to provide a sustainable packaging solution. The container can be recycled at PET recycling facilities, which are currently the most common recycling centers.

More competitive price

The materials crisis has caused significant disruption to the packaging market, particularly for aluminum, which typically commands a higher price than PET film.

Our 100% PET blister offers the same barrier qualities while reducing production costs, resulting in a more cost-effective product.

The only Spanish company with 100% PET blister

Rotor Print has announced the launch of its 100% PET blister product, making them the only Spanish company to offer this technology.

Huhtamaki launches Push Tab® blister lid, a first-to-market, aluminum-free

The pharmaceutical sector is being presented with a new opportunity to gain sustainable and eco-friendly packaging solutions on a global scale.