High-value pharmaceuticals, such as biologics, innovative drugs, or specialty tablets, are highly sensitive to environmental factors. Moisture, oxygen, and light are three major “hidden threats” that can degrade drug quality, reduce efficacy, and even compromise safety.
Blister packaging is widely adopted in the pharmaceutical industry for its ability to provide individual product protection, barrier properties, and quality control. This guide explains how blister packaging protects against moisture, oxygen, and light, ensuring drug stability throughout production, transportation, and storage.
Three Major Environmental Threats to Pill Quality
1. Moisture
Moisture can cause tablets to absorb water, soften, and have abnormal disintegration times. It can also lead to microbial contamination, reducing the stability and safety of the drug. Especially for tablets, capsules, and powders, high humidity is one of the main reasons for reduced drug efficacy.
2. Oxygen
Oxygen can oxidize the active ingredients in drugs, leading to decreased efficacy or even complete loss of effectiveness. For easily oxidized components, such as vitamins, hormones, and some biological drugs, the oxidation reaction is usually irreversible, directly affecting drug quality.
3. Light
Ultraviolet and visible light can damage drug molecular structures, leading to loss of efficacy. Photosensitive drugs such as hormones, vitamins, and enzyme preparations, if not protected from light by their packaging, are prone to degradation during transportation and storage.
How Blister Packaging Provides Protection
1. Individual Sealed Design
Each tablet is individually packaged, ensuring that opening one tablet does not affect the stability of other tablets. This design not only guarantees the freshness of the medication but also allows patients to use it as needed.
2. Selection of High-Barrier Materials
PVC/Alu Blister: Basic moisture and oxygen barrier, suitable for general solid dosage forms.
PVDC/PCTFE (Aclar) Composite Film: Enhanced moisture barrier performance, suitable for high-humidity environments.
Alu/Alu (Aluminum-Aluminum Cold Forming) Blister: Almost completely blocks water, oxygen, and light, suitable for high-value medications.
3. Film Thickness and Forming Process
The thickness of the blister and the forming process directly affect the barrier performance:
Thermoforming: Suitable for PVC/Alu blisters, fast forming speed.
Cold Forming: Suitable for Alu/Alu blisters, providing optimal barrier performance.
Precise equipment and process control can prevent thin spots or cracks, improving sealing reliability.
1. Precise Forming, Ensuring Blister Integrity
The quality of blister forming directly determines the protective capabilities of the packaging:
- Uniform forming depth
- Avoids thin spots and broken blisters
- Ensures complete encapsulation of the medication
High-performance blister packaging machines can stably control forming parameters, reducing the defect rate.
2. Stable Heat Sealing, Guaranteeing Long-Term Sealing Effect
Heat sealing is one of the most critical processes in blister packaging:
Temperature, pressure, and time must be precisely matched
Poor heat sealing can lead to "incomplete sealing" or "leaks"
This can easily lead to moisture absorption or oxidation during long-term storage
Advanced blister machines typically have a precise heat sealing control system to ensure consistent sealing of every blister pack.
3. Online Detection, Enhancing Packaging Reliability
Modern blister packaging machines usually integrate:
▪ Missing tablet detection
▪ Broken blister detection
▪ Seal integrity monitoring
Through the online detection system, unqualified products can be promptly removed during the packaging process, significantly improving the safety of the finished product.
Choosing the Right Blister Packaging Solution
1. Based on Drug Characteristics
High hygroscopicity → Prioritize high-barrier materials
Photosensitive or easily oxidized → Use aluminum-aluminum cold-formed blister packaging
2. Consider Market and Storage Conditions
High humidity or high temperature regions → Enhance moisture resistance
Long-distance transportation or exported pharmaceuticals → Higher barrier requirements
3. Equipment Selection Recommendations
Supports multiple materials (PVC, PVDC, Alu-Alu)
Modular design, adaptable to multi-SKU production
Quick mold changeover, reducing downtime and improving production efficiency
Conclusion
For high-value pharmaceuticals, packaging is not a cost, but rather an integral part of protecting the investment.
Through appropriate blister materials, stable forming and heat-sealing processes, and reliable blister packaging equipment, you can:
▪ Significantly extend the shelf life of pharmaceuticals
▪ Ensure efficacy and safety
▪ Protect brand reputation and patient interests
If you are looking for high-performance blister packaging equipment that is stable in operation and fully compliant with GMP requirements for your production line, please contact us immediately. We will provide you with customized blister packaging solutions perfectly tailored to your product needs.
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