As we work to embed sustainability through the lifecycle of our medicines and reduce environmental impact across our value chain, we are rethinking everything from how medicines are discovered and developed to how they are packaged and delivered, including the development of more sustainable blister packaging.
For more than 50 years, blister packs have been the packaging format of choice for oral solid-dose medicines (such as tablets and capsules) in many markets across the world. They protect products from damage, contamination and moisture, while making medication easy to identify, carry and use.
Traditional blister packs are typically made from combinations of polyvinyl chloride-based materials – such as PVC PVDC – and aluminium. While these materials help protect medicines, their production contributes to the packaging’s carbon footprint, and the combination of PVC-based materials and aluminium makes blister packs challenging to recycle through conventional waste streams.
Establishing a mono-material alternative for pharmaceutical packaging
Initial industry data suggests that replacing PVC-Aluminium based blisters with mono-polypropylene (PP) may reduce greenhouse gas (GHG) emissions.
We’re taking a life cycle approach to assess the potential impact across emissions, recyclability, resource use, waste management and the availability of appropriate recycling systems.
Our goal is to develop a more recyclable format while maintaining quality, safety and usability. Any new blister pack, while being more sustainable, must protect the medicine throughout its shelf life, run effectively on manufacturing lines, carry essential product and batch information, and meet stringent pharmaceutical quality and regulatory requirements.
We have developed innovative mono-PP materials and packaging line technologies designed to support efficient, robust production at scale. This work demonstrates how packaging innovation can deliver both operational performance and environmental objectives.
The transition to a mono-PP blister could also create opportunities to incorporate non- fossil fuel materials, such as bio-based materials, and chemically recycled content, potentially reducing reliance on virgin fossil-based materials. In parallel, we are optimising pack formats to reduce packaging size.
We are planning to launch products in PP blister packs from 2027.
Collaborating to accelerate progress
Collaboration across the pharmaceutical industry and wider value chain is essential to drive progress at scale. Strong partnership with material and equipment suppliers has been a key enabler to moving our strategy forward.
Through the Pharmaceutical Manufacturing Forum (PMF) Sustainable Blister Packaging Workstream, we’re exploring packaging innovation with other leading biopharmaceutical companies. Together, members of the Workstream have assessed technical, quality, manufacturing and regulatory challenges, evaluated mono-polymer options, and explored design-for-recycling principles.
Rethinking blister packaging is an important step in reducing the environmental impact of medicines. By combining scientific rigour, patient-centred design and collaboration across the industry, we are exploring solutions that can deliver meaningful sustainability benefits while maintaining the quality, safety and usability patients expect. This is a complex journey, but by working together we can help reshape a 50-year-old standard for a more sustainable future.
