In the world of pharmaceutical packaging, choosing the right blister pack isn’t just about sealing a product—it’s about safeguarding quality, ensuring compliance, and elevating patient safety. Among the most common materials used in blister packaging, Cold Form (Alu-Alu) and PVC (Polyvinyl Chloride) dominate the landscape. But which is the better fit for your formulation?
Let’s dive into the key differences, benefits, and considerations to help you make the right packaging choice for your next pharmaceutical product.
Understanding the Basics
1. PVC Blister Packaging
PVC is the most commonly used material for thermoformed blister packs. It’s a plastic film that, when heated, forms a cavity to hold tablets or capsules. It’s typically sealed with aluminum foil on the back.
2. Cold Form (Alu-Alu) Packaging
Cold-form packaging uses a laminate of aluminum, usually combined with polyamide and PVC layers. It’s formed without heat, using pressure to create cavities. This process results in an ultra-high barrier pack that’s completely opaque.
3. Cold Form vs. PVC: The Face-Off
| Feature | PVC | Cold Form (Alu Alu) |
| Barrier Protection | Moderate | Excellent (100% barrier) |
| Visibility | Transparent | Opaque |
| Cost | Lower | Higher |
| Forming Process | Thermoforming | Cold forming |
| Shelf Life | Standard | Extended |
| Sustainability | Limited | Higher (PVC-free options available) |
| Applications | Stable drugs | Sensitive formulations |
When to Choose PVC Blister Packs
PVC is often the go-to solution for cost-sensitive projects or when the drug does not require high-barrier protection. It’s lightweight, easy to process, and offers product visibility—an important aspect for patient trust and compliance.
Ideal for:
- Stable formulations
- High-volume OTC drugs
- Products requiring visual inspection
When to Choose Cold Form Blister Packs
Cold-form packaging is all about protection. Its high-barrier structure shields medications from moisture, oxygen, and light, making it perfect for sensitive APIs and international distribution where varying climates are a concern.
Ideal for:
- Moisture-sensitive formulations
- Light-sensitive drugs
- High-value pharmaceuticals
- Global distribution
Regulatory Considerations
Both materials are accepted by major health authorities, but with rising environmental demands, Alu-Alu packaging is becoming more favored—especially with PVC-free and recyclable alternatives.
At Sanwariya Packaging, we offer compliant, future-forward foil solutions that align with FDA, EMA, TGA, and WHO standards.
A Strategic Packaging Decision
The choice between Cold Form and PVC isn’t just a technical one—it’s strategic. It impacts product integrity, brand reputation, logistics, and ultimately, patient health. That’s why it’s crucial to work with a packaging partner who understands the science behind the solution.
Why Partner with Sanwariya Packaging?
We specialize in pharmaceutical-grade blister foils tailored to your specific requirements—whether you’re scaling an affordable OTC product or launching a breakthrough, high-value drug.
- PVC-compatible lidding foils with custom print and security features
- Cold-form Alu-Alu laminates for ultimate barrier protection
- Fully compliant materials across regulatory zones
- Eco-conscious options with NC-free and recyclable foil technologies
Let’s make your packaging a competitive advantage.
Contact us today to explore how Sanwariya Packaging can help you choose the right blister foil and stand out in a competitive pharmaceutical market.
