What is Alu-Alu Blister Foil?
Alu-Alu blister packaging is a type of pharmaceutical packaging made of multi-layer composite materials, with both the base and lid made of aluminum foil.
Alu-Alu Blister Foil effectively blocks moisture, oxygen, and light, making it an ideal choice for sensitive drugs that require maximum protection and extended shelf life.
Alu-Alu Blister Foil Specification
Alu-Alu blister packaging typically uses a multi-layer structure, including oriented polyamide (OPA), aluminum foil, and polyvinyl chloride (PVC) films. Common specifications include a total thickness of 130–160 μm, with the OPA layer thickness of 25–30 μm, aluminum foil layer thickness of 45–60 μm, and PVC layer thickness of 60 μm. The alloy used is usually soft temper 8021 aluminum. Other specifications include width of 60–1000 mm and core diameter of 76 mm.
| Item | Specification |
| Alloy | 8021, Soft Temper |
| Width | 60–1000 mm |
| Core ID | 76 mm (paper or plastic core) |
| Outer Diameter | Max 500 mm |
| Thickness Tolerance | ≤ ±5% |
Alu-Alu Blister Foil Structure and Composition
- Outer Layer (25 μm): Oriented Polyamide (OPA), provides mechanical strength and forming toughness
- Core Layer (45–60 μm): Pure Aluminum Foil, provides excellent barrier performance
- Inner Layer (60 μm): Heat-seal layer (PVC or PVC alternative), used to seal with the top aluminum foil
| Item | Specification |
| OPA (Oriented Polyamide) | 25–30 μm |
| Aluminum Foil | 45–60 μm (8021 Alloy, Soft) |
| PVC | 60 μm |
| Adhesive | For bonding layers |
| Total Thickness | 130–160 μm |
Alu-Alu Blister Foil Features and Advantages
- Excellent barrier performance, effectively blocks moisture, oxygen, and light
- Good sealing performance, no pinholes
- High strength and high ductility
- Suitable for various drugs, such as tablets, capsules, and powders
- Can be printed with custom designs according to customer requirements
- Superior barrier performance: 100% protection against light, oxygen, and moisture, protecting products from degradation and hydrolysis.
- Enhanced product stability: Provides comprehensive environmental protection, helping drugs maintain stability and extend shelf life, especially for highly sensitive or hygroscopic formulations.
- Attractive appearance: High-value glossy finish, can be printed with brand logos and patient information.
- Customizable: Can be made into various blister designs and produced in different thicknesses according to specific requirements.
- Cold forming process: Can be formed without heating, directly stamped into blisters through high-pressure molds.
- Safe and convenient: Aluminum foil must be broken when tampered, providing a clear opening indication.
- Sustainable and eco-friendly: Aluminum recycling rate exceeds 90%, much higher than plastic.
Alu-Alu Blister Foil Applications
- Highly hygroscopic drugs: drugs that easily absorb moisture from the air.
- Light-sensitive formulations: e.g., nitroglycerin, nifedipine, etc.
- Oxygen-sensitive biologics and active pharmaceutical ingredients.
- Effervescent tablets: drugs that react strongly with environmental moisture.
- Vaccines and other sensitive biological products.
- Any drugs that require long-term storage under harsh environmental conditions.
Pharmaceutical Industry (Main Applications):
- Drugs sensitive to high humidity: antibiotics, vitamins, effervescent tablets
- Highly active / highly toxic drugs: anticancer drugs, hormone replacement therapy drugs
- Drugs requiring long-term storage: vaccines, biologics (extend shelf life by 30–50%)
- Drugs exported to humid and hot regions: provides full protection
Other Fields:
- High-end health supplements and nutraceuticals
- Diagnostic kits (ensure test accuracy)
- Specialty foods (e.g., premium tea, spices)
- Veterinary drugs and animal health products
Alu-Alu Blister Foil vs Traditional Packaging
| Feature | Alu-Alu Blister Foil | PVC Blister + Aluminum Lid |
| Barrier Performance | Total barrier | Limited barrier |
| Moisture Resistance | 100% waterproof | Partially permeable |
| Shelf Life | Extended 30–50% | Standard |
| Temperature Range | -80℃ to +200℃ | Limited heat resistance |
| Transparency | Opaque (cannot view product directly) | Transparent (product visible) |
| Cost | Higher | Economical |
| Environmental Friendliness | Highly recyclable (90%+) | Difficult to recycle |
| Suitable Products | Highly sensitive drugs, long-term storage products | Ordinary drugs, daily-use products |
Alu-Alu Blister Foil Comparison with Other Blister Lidding Materials
| Feature | Alu-Alu Foil | PVC/PVDC with Aluminum Lidding | Paper-Push-Through (PPT) |
| Barrier | Excellent (Total) | Good (but not perfect for highly sensitive drugs) | Poor (not a true barrier) |
| Push-Through | Easy (peel-push) | Very Easy (peel-push) | Child-Resistant (peel-peel) |
| Primary Use | Moisture/Oxygen/Light-sensitive drugs, vaccines. | Standard, less sensitive medications. | Where child resistance is a higher priority than a high barrier. |
| Cost | Higher | Lower | Moderate |
Alu-Alu Blister Foil FAQs
What is the difference between blister and Alu Alu packing?
The main difference lies in material structure and protection level:
Standard blister packaging uses PVC/PVDC or PVC/ALU, with only the base or top layer containing aluminum.
- Medium barrier performance
- Lightweight
- Commonly used for ordinary tablets and capsules
Alu-Alu packaging (cold form blister) uses aluminum on both sides (OPA-AL-PVC).
- Highest barrier against moisture, oxygen, light, and contamination
- Suitable for sensitive drugs
- Longer shelf life
Alu-Alu packaging provides a 100% light-blocking, high-barrier solution, while standard blister packaging offers only partial protection.
What is an Alu Alu cold form blister?
An Alu-Alu cold form blister is a pharmaceutical packaging made of multi-layer composite structure:
OPA (nylon)/Aluminum/PVC.
Cold forming process: the aluminum foil laminate is mechanically pressed into molds without heating.
Main features:
- Excellent forming strength
- Highest barrier protection
- Suitable for hygroscopic, light-sensitive, or oxygen-sensitive drugs
- Widely used for tablets, capsules, and high-value drug packaging
What is the use of blister foil?
Blister foil is used for unit-dose pharmaceutical packaging, mainly for:
- Sealing tablets and capsules inside the blister
- Protecting contents from moisture, oxygen, and light
- Ensuring longer shelf life and safety
- Providing tamper-evident packaging
- Easy removal of tablets by push or peel
In Alu-Alu packaging, blister foil provides a complete barrier layer, maintaining drug stability and quality over the long term.