New Process Enables Recycling of Pharmaceutical Blister Packs

A new, low-cost thermo-mechanical process developed by researchers at the Universidad de Concepción in Chile offers a potential solution for recycling pharmaceutical blister packs, a type of packaging historically difficult to recycle due to its multi-layer composition. The innovation, born from a collaboration between the university and the independent pharmacy network Redfarma, addresses a significant waste stream that typically ends up in landfills.

The Challenge of Pharmaceutical Blister Pack Recycling

Pharmaceutical blister packs are commonly used to package pills and tablets, protecting them from environmental factors like oxygen, humidity and light [1]. These packs typically consist of a plastic sheet (often PVC, PVDC, or PET) sealed to an aluminum sheet, creating a robust barrier but also a recycling challenge. “It is generally made up of a plastic sheet…sealed with an aluminum sheet, which makes it difficult to recycle, as both materials remain firmly adhered,” explained Dr. Carlos Lanziotti Muñoz, the researcher leading the project [1].

How the New Process Works

The process developed by Dr. Lanziotti Muñoz and his team begins with a heat treatment to weaken the bond between the aluminum and plastic. This is followed by a thermo-mechanical stage that physically separates the two materials [1]. The separated components are then classified by density, dried to remove moisture, and crushed into flakes less than 10 millimeters in size. The method is reportedly applicable to blisters from various pharmaceutical laboratories and formulations, even those with multiple polymer layers [1].

Reducing Environmental Impact

A key benefit of this process is its reduction of hydrochloric acid (HCl) emissions. Many pharmaceutical blisters utilize PVC or PVDC, which contain chlorine and can release harmful HCl gas when heated. The new process significantly minimizes this release, protecting both equipment and operators [1].

The recovered plastic can be reprocessed into new products via thermoforming, whereas the aluminum can be melted down and reused as raw material. This approach contributes to a circular economy and reduces the environmental footprint of pharmaceutical packaging.

Broader Trends in Sustainable Pharmaceutical Packaging

This innovation aligns with a growing trend toward sustainability in the pharmaceutical industry. Alternatives to traditional blister packs include single-material blisters (like polypropylene) and packaging made from paper, cardboard fibers, or biodegradable plastics derived from sources like corn starch or sugar cane [1]. Experts emphasize the importance of incorporating sustainability criteria into pharmaceutical packaging alongside quality and safety standards.

About Dr. Carlos Lanziotti Muñoz

Dr. Carlos Lanziotti Muñoz is an academic at the Faculty of Engineering at the Universidad de Concepción in Chile. His research focuses on engineering and materials science, with a strong emphasis on innovation and sustainability [2], [3].