Pharmaceutical packaging plays a critical role in ensuring the safety, stability, and efficacy of medications. Among all the packaging solutions, Alu-Alu (cold form aluminum-aluminum) packaging and Alu-PVC Packaging are two widely used packaging options, each offering distinct advantages. This article compares these methods, analyzing their advantages and disadvantages and offer insights for pharmaceutical manufacturers in choosing the rightpackaging solutions.

1. What is Alu-Alu Packaging?

Alu-Alu packaging, also referred to as cold form blister packaging, is manufactured by compressing a multi-layer aluminum-based material into specific shapes as per the requirement of production. The formed cavities securely hold pharmaceutical products, preventing exposure to air, humidity, and light. This ensures that the integrity of tablets, pills or drugs remains intact throughout storage and distribution, making it ideal for medications requiring strict stability conditions.

Alu-Alu packaging provides a 100% protection against environmental factors, making it an excellent choice for highly sensitive pharmaceutical products.

2. What is Alu-PVC Packaging?

Alu-PVC Packaging is a combination of plastic (PVC, PVDC, or PET) and aluminum foil, creating a visible, lightweight, and cost-effective packaging solution. It provides visibility, ease of use, and customizable designs for different types of medicines and drugs, making it one of the most widely used pharmaceutical packing formats.

3. Key Differences Between Alu-Alu and Alu-PVC Packaging

Both Alu-Alu and Alu-PVC blister packs are widely used in pharmaceutical packaging,  their differences in materials, protection levels, and shelf life etc, make each suitable for specific applications. Below is a quick reference chart to help you better understand the key distinctions:

In addition to the brief table above, we will analyse their major differences in terms of material composition, cost, barrier protection, product visibility and design as well as environmental considerations in the following section.

1) Material Composition of Alu-Alu vs Alu-PVC Packaging

• Alu-Alu Blister Packaging:
  Alu-Alublister packs consist of two layers of aluminum foil. The top layer is usually a soft aluminum foil that can be heat-sealed to form a cavity for the pharmaceutical product, while the bottom layer is a more rigid aluminum foil that provides additional protection. This dual-layer structure offers a high barrier against external factors like moisture, light, and oxygen.
• Alu-PVC Blister Packaging:
  Alu-PVCblister packs are made up of a PVC base that is molded into a cavity for the pharmaceutical product, with an aluminum foil backing that seals the product in place. The PVC layer offers a semi-rigid structure, and the aluminum foil layer provides a moisture and light barrier, but the overall protection is less robust compared to Alu-Alu

2) Cost comparison between Alu-Alu and Alu-PVC packaging

It is researched that the price difference between Alu-Alu and Alu-PVC packaging can range from 25% to 40% higher for Alu-Alu packing solution, depending on the order volume and specific packaging requirements.

• Alu-Alu Blister Packaging:
  Due to the use of two layers of aluminum foil, Alu-Alu blister packs tend to be more expensive in terms of both raw materials and production processes.Therefore, Alu-Alu packing method is more suitable for high-value or sensitive pharmaceutical products that require optimal protection.
• Alu-PVC Blister Packaging:
  On the other hand,Alu-PVC blister packs are more cost-effective due to the combination of PVC and a single aluminum foil layer. Alu-PVC blister packs is a popular choice for products that do not require high levels of protection but still benefit from a barrier against environmental contaminants.

3) Barrier Protection Difference of Alu-Alu vs Alu-PVC Packaging

• Alu-Alu Blister Packaging:
  Alu-Alu blister packs provide superior barrier properties, making them the ideal choice for moisture-sensitive pharmaceuticals, including certain tablets and capsules. The two aluminum layers effectively protect the product from moisture, light, and oxygen, which helps to extend shelf life and preserve the drug’s potency.
• Alu-PVC Blister Packaging:
  While Alu-PVC blister packs do offer some degree of protection against moisture and light, the PVC layer does not provide as strong of a barrier as the dual aluminum layers found in Alu-Alu. As a result, Alu-PVCpacking is best suited for products that are less sensitive to environmental factors or have a shorter shelf life.

4) Product Visibility and Design of Alu-Alu vs Alu-PVC Packaging

• Alu-Alu Packaging:

Alu-Alu blister packs, with their dual layers of aluminum, offer excellent protection but generally limit product visibility. The opaque aluminum layers typically prevent consumers from seeing the product inside. This can be a disadvantage for products where visual appeal or brand recognition is important.

• Alu-PVC Packaging:

In contrast, Alu-PVC blister packs offer better product visibility due to the transparent nature of the PVC layer. This makes it easier for consumers to see the product inside, which can be a strong selling point for products like tablets, capsules, and soft gels that benefit from visual appeal.

The ability to showcase the product inside can help improve consumer trust and increase product attractiveness on store shelves. Moreover, Alu-PVC packing can be easily molded into custom shapes, allowing for more creative and visually appealing designs that align with branding efforts.

5) Environmental Considerations of Alu-Alu vs Alu-PVC Packaging

• Alu-Alu Blister Packaging:
  One of the environmental concerns withAlu-Alu blister packs is their reliance on aluminum, which is energy-intensive to produce. However, aluminum is also highly recyclable, so it can be repurposed if properly disposed of, therefore it can be considered as a more sustainable pharmaceutical packaging solutions.
• Alu-PVC Blister Packaging:
  Alu-PVC blister packs are also recyclable, though the PVC material is more difficult to recycle compared to aluminum. PVC poses more environmental challenges because it’s more likely to release toxic substances when burned or improperly disposed of, which can raise concerns for environmentally conscious manufacturers.

4. Manufacturing Process of Alu-Alu Packaging and Alu-PVC Packaging

The manufacturing processes for Alu-Alu and Alu-PVC packing involve multiple stages, each tailored to the unique material properties and end-use requirements. Both methods aim to protect pharmaceutical products while maintaining efficiency and cost-effectiveness. However, the techniques for the productions are slightly different. Here’s table to see the overall difference for the automated production of Alu-Alu packaging and Alu-PVC packaging.

1) How to Make Alu-Alu and Alu-PVC Packaging?

For the production of Alu-Alu Packaging or Alu-PVC Packaging, it usually requires special machines – Alu-Alu/Alu-PVC Blister Packing machine. The whole process includes few step: forming, feeding, sealing, indention and cutting. The manufacturing process is slightly different for this two packaging options.

• Forming

Alu-Alu Packaging is using cold forming method which requires high pressure to complete the formation of the blister cavities.

WhereasAlu-PVC Packaging is adopting thermoforming method. PVC film is heated and then formed into cavities using vacuum pressure.

Photo credit: jinlupacking.com

• Feeding: 

The two blister packaging methods are going through the same process for the feeding process where the feeder is dispensing materials such as capsules into the blister cavities.

Photo credit: jinlupacking.com

• Sealingand Indentation

Both of the blister packaging options have the same sealing process where the lidding aluminium foil is sealed using heat and pressure to ensure airtight packaging.

Indentation lines are created on the sealed blister sheet for both Alu-Alu or Alu-PVC Packaging. Batch numbers, production dates and some other required information will be created at this step.

Photo credit: jinlupacking.com

• Cutting:

After the indentation, the blister sheet is cut into individual blister packs. This step is no different for producing Alu-Alu or Alu-PVC blister packs.

Photo credit: jinlupacking.com

2) Difference of Alu-Alu vs. Alu-PVC Production Process

As a small summary for the comparison of the two production methods at each working station, you can take a look for the below table.

For a better understanding of the working process for the production of Alu-Alu Packaging and Alu-PVC blister packaging, you can click below the videos from JinluPacking.

[jl_youtube src=”https://www.youtube.com/embed/k0uyYbGttCU”]

5. How to Choose the Right Packaging for Your Product?

The choice between Alu-Alu packaging and Alu-PVC Packaging depends on various factors, including the nature of the medicines, storage conditions, and budget constraints. Choosing between Alu-Alu Packaging and Alu-PVC Packaging depends on several factors.

1) Product Sensitivity

• If your medication is highly sensitive to moisture, oxygen, and light, Alu-Alu packagingmethod is the better choice due to its superior barrier properties.
• If the medicine doesn’t require extreme protection, Alu-PVCpackaging option provides sufficient defense while remaining cost-effective.

2) Cost Considerations

• Alu-Alu packagingis more expensive because it uses high-quality materials and a more intricate production process.
• Alu-PVC packaging, on the other hand, is budget-friendly and preferred for mass-market medications, offering a more economical solution without compromising basic protection.

3) Consumer Experience & Branding

• If customer trust and transparency are key, Alu-PVC packing methodallows for easy visual inspection of the product, which can be a valuable marketing tool.
• Alu-Alu packaging, however, offers enhanced security with tamper-proof seals, ensuring the integrity and safety of the medication, which may be essential for higher-value or sensitive products.

4) Regulatory Requirements

• Some regions and regulatory standards require higher levels of protection, making Alu-Alu packagingthe necessary option for certain pharmaceutical products.
• For dietary supplements and over-the-counter drugs, Alu-PVC packagingis generally accepted and complies with the regulatory requirements for these less sensitive products.

6. Conclusion

Both Alu-Alu packaging and Alu-PVC Packaging have their unique advantages and drawbacks. While Alu-Alu packaging excels in protection and durability, Alu-PVC Packaging is more cost-effective and user-friendly. Understanding the differences between these two options, together of taking into consideration for the few factors we mentioned in the article, you can choose t the best solution for your specific needs.