Blister packs are a ubiquitous presence in our medicine cabinets, protecting medications and other products. But beyond convenience, a new question is emerging: can these familiar packages become more sustainable? This interview dives deep into the world of blister pack film technology.
We’ll explore how manufacturers are pushing the boundaries of innovation to create eco-friendly solutions without compromising the crucial functions of product protection and security.
Join us, as Quateel Ahmad, Chief Operating Officer at Jackpak Industries, sheds light on the latest advancements in blister pack film technology.
How are blister packing film manufacturers innovating to create more eco-friendly blister packs, and what are the challenges they face in this transition?
As someone who works with blister packing material, I know how ubiquitous and useful these are. Pound for pound, blister packs protect and deliver more dosages than any other form securely and in the most economical manner. Processing of these is easy and less energy dependent as compared to other materials. That makes it a good material in terms of ecological footprint.
That said, when it comes to recycling blister packing the issue is in how they’re built. Most blister packs combine plastic for the forming body and aluminum foil for the back. When you press the blister the plastic deforms but the aluminum foil does not, thus breaking and releasing the dose at the time of use. These are fused together for the rest of the pack. Making it difficult for recycling facilities to separate them, Thankfully, there’s a wave of innovation happening to create more sustainable blister packs.
One of the solutions being pursued is single-material blister packs. Here, both the body and backing would be made from the same recyclable material. The challenge, however, is figuring out how to make this material thermoformable while still being recyclable. Another approach is exploring biodegradable plastics for blister packs. These materials would break down much faster, reducing their impact on the environment. Advancements in sorting technology and educating consumers on proper disposal methods could also significantly improve recycling efforts. By working together– packaging manufacturers, recycling companies, and consumers alike– we can find effective solutions for a more sustainable future where blister packs don’t become environmental burdens.
With the rise of e-commerce, there’s a growing need for blister packs that can withstand the rigors of shipping. How are blister packing film manufacturers addressing this challenge, and what are some emerging trends in puncture-resistant and tamper-evident blister packs?
Once the medicines leave the factory, it is up to the supply chain to deliver these in the best of conditions.
The chain in countries like India is quick and it reaches the product shelf in the warehouse or retail shelf speedily. Ecommerce in pharma is now a distributor or retailer led fulfilment so it is much like a customer delivery ordered locally and doesn’t put additional stress on the packaging. For centrally compiled orders the packaging is well guarded by layers of paper and bubble wrap. For expensive or sensitive materials there are monocartons or duo carton containing one or two blister packs respectively. Even if unboxed the blister packaging integrity is usually unchanged in the normal packing process.
What technological advancements are being made in blister pack films to ensure product safety and patient safety?
Packaging developers are constantly working to keeping medications safe while being environmentally responsible. Here’s the challenge: product safety, which basically means how well protected the medication is, can clash with sustainability goals. Traditional blister packs rely on a mix of materials like aluminum foil and different plastics to create a super strong barrier against contamination. Think alu-alu (aluminum laminated to polyethylene), PVC laminated with barrier films or PVC coated with PVdC. While this keeps the meds safe, it makes recycling challenging as separating all those materials is a complex process.
But there is progress being made. Single complex plastics are being developed that can be isolated, but are some ways off. For patient safety, blister pack design itself can actually create the difference. For example, color coding of packs helps people differentiate medications, especially important for folks juggling multiple prescriptions. Blister packs can also be designed with compartments marked for specific times of day, like morning and evening, to help patients stick to their medication schedule. This reduces the risk of missed or double doses, particularly for those who might forget.
These advancements highlight the ongoing efforts to find a balance: keeping medications safe while making blister packs more eco-friendly. It’s a constant work in progress, but we’re moving in the right direction.
How can blister packing film technology be leveraged to enhance product security and brand protection to address the serious concern of counterfeiting?
The fight against counterfeit medications is a relentless struggle. We make progress with security features– tamper-evident containers, hidden watermarks, micro-printing making it tougher for the bad guys. But it’s a never-ending game. These measures make things more difficult, but they’re not a silver bullet. The level of protection a medication needs depends on its popularity. The more in demand, the more we have to step up our security game.
Traditional methods like holograms on packs or markings on the tablets themselves? Honestly, not that much of a barrier anymore. With enough resources and know-how, they can be mimicked. Plus, they focus on the product itself, not necessarily any weaknesses in the blister pack technology.
Here’s where things get a little more interesting. We have existing technology like QR codes and barcodes printed on the packaging. These allow consumers to scan and verify the product’s authenticity, track its journey from factory to pharmacy. But even these have limitations. Counterfeiters can potentially replicate codes or find ways to exploit loopholes in the verification process.
So, what’s the answer? It’s a multi-pronged attack. We need collaboration between pharmaceutical companies, packaging manufacturers, regulators, and even law enforcement. Continued research and development is key to finding and implementing new anti-counterfeiting tech. But not ot forget consumer education! Equipping patients with the knowledge buy sensibly from reliable suppliers and pharmacies, teach them how to spot and report suspicious packaging can seriously disrupt counterfeit operations.
What are the latest developments in film materials and coatings that improve the shelf life and integrity of packaged products?
Looking ahead, things like oxygen scrubbers and desiccant tablets within the blister pack show a lot of promise. Connected to individual blisters by hollow channels, these inserts actively remove oxygen and moisture to prevent medication degradation, offering an active barrier compared to the traditional passive designs.
These have been more common for bottled products, but are now used in blister packs as well, especially for those with very sensitive ingredients. There’s more to maintaining blister pack integrity than just those extras, though. Tropical packs designed to fight high humidity are not new. These work well in some regions, but are not needed or as effective everywhere. Something I’ve found to be efficiently effective is placing blister packs inside sealed laminated pouches. This creates an additional barrier, protecting the package from all sides unlike tropical packs that only cover the PVC side. This extra layer offers significantly better overall protection. When this pouch is made with high-barrier films it increases the shelf life.
Most Blister film users use advanced pinhole detection and rigorous quality control for both the backing and forming foils. These are crucial elements for keeping the package airtight and protecting the product. Additionally, high-quality machines ensure strong seals during the packaging process. But even with the best materials, improper machine maintenance can negatively impact package integrity and shelf life. That’s why I always advise my customers to prioritize regular maintenance and upgrades for their sealing parts and forming equipment. Finally, using the right change parts is essential. A change part designed for PVC wouldn’t work optimally with laminated film. The mold wouldn’t be aligned correctly, and the blisters wouldn’t form with the intended properties.
The key takeaway here is that blister pack performance is a combination of factors. It’s not just about the film itself; it’s also about the material, the design of the change parts, the performance of the machine, and everything working together in harmony.
Blister packs can sometimes be difficult to open for elderly or disabled consumers. Are there any advancements in blister pack film design or functionality that can improve ease of use?
One significant development is the peel-off blister pack. These work just like regular blister packs in terms of keeping your medication safe, but instead of pushing through the tablet or capsule, you can just peel off a little flap at the edge for each dose. It’s not sealed, more like a tear-away tab. This is great not just for people who have trouble pushing down, but also for medications that are delicate.
Some softer tablets and capsules can crumble if you push on them too hard. And the blister foil does need a certain amount of force to tear. And to keep the medication safe, sometimes makers have to use a thicker film on the bottom of the pack. That can make it trickier to push the medication out. Peel-off packs are a way around that. They can use materials like easy-tear paper or other things that are easier to open. So, these advancements are good for people who might have trouble with their hands, but also for those delicate medications. Also a now common design feature is the perforation for each dose so for a blister pack you do not have to carry a full blister of your flu medication for example. You can just tear and carry one dose and consume when needed.
