Which Material is Used in Pharmaceutical Packaging?

The packaging of pharmaceutical products is a matter of utmost seriousness, directly impacting drug efficacy, safety, and patient health. The materials used must meet stringent quality and regulatory standards.

Common materials used in pharmaceutical packaging include glass (borosilicate, soda-lime), plastics (HDPE, LDPE, PP, PET, PVC), metals (aluminum, tinplate), and paper/paperboard. The choice depends on the drug’s properties, dosage form, protection requirements, and regulatory compliance.

Pharmaceutical packaging is a highly specialized field where material science, drug stability, and patient safety intersect. While ShineTop primarily focuses on cosmetic packaging, the principles of material integrity and protection are shared, and we sometimes produce components like glass vials or specific plastic containers that can also serve pharmaceutical needs. Let’s explore the critical materials used in this vital sector.

What Metals Are Used in Pharmaceutical Packaging?

Metals offer excellent barrier properties and durability, making them suitable for certain pharmaceutical applications, especially where protection from light, moisture, and gases is paramount.

The primary metals used in pharmaceutical packaging are aluminum (for blister packs, foils, tubes, cans, closures) and occasionally tinplate (for some containers or closures). Stainless steel may be used for specialized equipment or reusable containers but is less common for primary drug packaging.

Metal’s impermeability and strength are key reasons for its use in protecting sensitive drug formulations.

Common Metal Applications in Pharma Packaging:

1. Aluminum:

   • Blister Packs (Foil): Aluminum foil (often hard-tempered or soft-tempered and laminated with plastic films or heat-seal coatings) is extensively used as the lidding material for blister packs containing tablets and capsules. It provides an excellent barrier to moisture, light, and gases, and allows for individual, tamper-evident dosing.
   • Collapsible Tubes: Used for ointments, creams, and gels. Aluminum tubes offer good barrier properties, prevent product suck-back (reducing contamination risk), and allow for near-complete product evacuation. They are typically internally lined with a protective lacquer.
   • Sachets & Pouches: Laminated aluminum foils are used for single-dose powders or liquids, offering excellent protection.
   • Aerosol Cans: For metered-dose inhalers (MDIs) or topical sprays.
   • Caps & Closures: Aluminum caps (e.g., ROPP – Roll-On Pilfer-Proof caps) are used on glass or plastic bottles for a secure seal. Vial seals often have an aluminum overseal.
   • Bags & Liners: For bulk storage or transport of sensitive pharmaceutical ingredients.

2. Tinplate (Tin-Coated Steel):

   • Containers: Less common for direct drug contact than aluminum but can be used for some bulk powders, ointments in tins (though aluminum is more prevalent now), or as robust outer containers.
   • Closures: Some screw caps or lids.

3. Stainless Steel:

   • While not typically primary packaging for dispensed drugs, stainless steel is used for:
     • Manufacturing equipment (vats, pipes).
     • Reusable containers for bulk drug substances or sterile solutions in hospital settings.
     • Some components of delivery devices.

Why these metals?

• Aluminum: Lightweight, excellent barrier, highly formable, good thermal conductivity (for sterilization), non-toxic (when properly treated/lined), and highly recyclable.
• Tinplate: Strong, good barrier, but heavier than aluminum and requires tin coating to prevent steel corrosion.
• Stainless Steel: Extremely durable, highly corrosion-resistant, easily cleanable and sterilizable, but expensive.

The choice of metal and any necessary internal coatings is critical to ensure no interaction between the metal and the drug product.

What are the 4 Types of Materials That Used in Packaging?

While many specific materials exist, packaging materials can generally be categorized into a few broad types based on their origin and primary characteristics.

The four main umbrella types of materials used in packaging are: 1. Glass, 2. Plastics, 3. Metals, and 4. Paper & Paperboard. Each category encompasses a variety of specific materials with unique properties.

These four categories form the backbone of the packaging industry, serving diverse needs across all sectors, including pharmaceuticals.

Overview of the Four Main Material Types:

1. Glass:

   • Composition: Primarily made from silica (sand), soda ash, and limestone.
   • Properties: Transparent (can be colored), inert, impermeable, excellent barrier, premium feel, infinitely recyclable, can withstand high sterilization temperatures.
   • Pharma Uses: Bottles for liquids (oral, parenteral), vials, ampoules, jars for ointments.
   • Cosmetic Uses (ShineTop’s Focus): Jars for creams, bottles for serums and perfumes, dropper bottles.

2. Plastics:

   • Composition: Synthetic polymers derived mainly from petroleum or natural gas (though bio-based plastics are emerging).
   • Properties: Lightweight, versatile (can be rigid or flexible), shatter-resistant, cost-effective, variable barrier properties depending on type.
   • Pharma Uses: Bottles for tablets/capsules/liquids, blister pack forming webs, tubes, closures, syringes, IV bags.
   • Cosmetic Uses (ShineTop’s Focus): Bottles, jars, tubes, compacts, caps, airless pumps.

3. Metals:

   • Composition: Primarily aluminum and steel (tinplate, tin-free steel).
   • Properties: Strong, excellent barrier, durable, recyclable, can be opaque or reflective.
   • Pharma Uses: Blister foils, tubes, aerosol cans, caps, seals.
   • Cosmetic Uses (ShineTop’s Focus): Tins for balms, aluminum tubes, caps, decorative components for perfume bottles.

4. Paper & Paperboard:

   • Composition: Made from wood pulp (virgin or recycled fibers) or other plant fibers.
   • Properties: Lightweight, printable, recyclable, biodegradable (if uncoated), versatile for structural design (boxes).
   • Pharma Uses: Secondary packaging (cartons for blister packs, bottles, tubes), labels, patient information leaflets (PILs), some primary packaging for dry powders if lined.
   • Cosmetic Uses (ShineTop’s Focus): Secondary boxes for all types of cosmetics, gift sets, labels, inserts.

Each of these material types has numerous sub-categories and grades specifically developed for particular packaging applications, including the stringent demands of the pharmaceutical industry.

Which Type of Plastic is Used in Pharma Packaging?

Plastics are extensively used in pharmaceutical packaging due to their versatility, light weight, and cost-effectiveness. However, not all plastics are suitable, and specific grades are required.

Common types of plastic used in pharma packaging include High-Density Polyethylene (HDPE) for bottles; Low-Density Polyethylene (LDPE) for squeeze bottles and films; Polypropylene (PP) for bottles, closures, and syringes; Polyethylene Terephthalate (PET/PETG) for bottles and some blister packs; and Polyvinyl Chloride (PVC) for blister packs. All must be pharmaceutical grade.

The selection of a specific plastic for pharmaceutical use is governed by its chemical resistance, barrier properties, physical strength, clarity, and compatibility with the drug product and sterilization methods.

Key Plastics in Pharmaceutical Packaging:

1. High-Density Polyethylene (HDPE – Resin Code #2):

   • Properties: Good moisture barrier, good chemical resistance, rigid, strong.
   • Uses: Bottles for solid dosage forms (tablets, capsules), some liquid medications.

2. Low-Density Polyethylene (LDPE – Resin Code #4):

   • Properties: Flexible, good moisture barrier, relatively inert.
   • Uses: Squeeze bottles (e.g., for eye drops, nasal sprays), films for bags and liners, components of closures.

3. Polypropylene (PP – Resin Code #5):

   • Properties: Good chemical resistance, good moisture barrier, high melting point (can withstand autoclaving/steam sterilization), good clarity in some forms (clarified PP).
   • Uses: Bottles for liquids and solids, closures (caps), syringe barrels and plungers, some flexible packaging.

4. Polyethylene Terephthalate (PET, PETG – Resin Code #1):

   • Properties: Excellent clarity, good strength, good barrier to gases (like oxygen) and moisture. PETG is a glycol-modified version with enhanced clarity and impact resistance.
   • Uses: Bottles for liquid oral medications, some ophthalmic solutions. PET films are used in some blister pack structures.

5. Polyvinyl Chloride (PVC – Resin Code #3):

   • Properties: Good clarity, rigid, good thermoformability, good chemical resistance.
   • Uses: Predominantly for the thermoformed base web of blister packs for tablets and capsules. Can also be used for some bottles (though less common now due to environmental concerns with PVC).

6. Polystyrene (PS – Resin Code #6):

   • Properties: Clear, rigid, but can be brittle.
   • Uses: Less common for primary drug contact but may be used for some diagnostic kits, trays, or secondary packaging components.

Important Considerations for Pharma Plastics:

• Pharmaceutical Grade: Plastics must meet specific regulatory standards (e.g., USP, EP, JP) for purity, extractables, and leachables.
• Sterilization Compatibility: The chosen plastic must be able to withstand the intended sterilization method (e.g., gamma irradiation, ethylene oxide, autoclaving) without degrading or deforming.
• Drug Interaction: Extensive testing is done to ensure no harmful interaction between the plastic and the drug product.

What Material is Most Used in Packaging?

When looking at the entire packaging landscape across all industries globally, one material category tends to dominate in terms of volume, though this can vary by region and specific application.

Globally, plastics are often cited as the most used material in packaging by volume, due to their versatility, light weight, cost-effectiveness, and wide range of applications. However, paper and paperboard also hold a very significant share, particularly for secondary and transport packaging.

The dominance of certain materials is driven by a combination of factors including cost, performance characteristics, and suitability for high-volume applications.

Dominant Packaging Materials & Reasons:

1. Plastics:

   • Why Widely Used:
     • Versatility: Can be molded into countless shapes and forms (bottles, films, trays, closures).
     • Lightweight: Reduces transportation costs and energy.
     • Cost-Effective: Generally lower production costs compared to glass or metal for many applications.
     • Durability & Shatter Resistance: Offers good protection against breakage.
     • Barrier Properties: Can be engineered to provide specific barriers to moisture, gases, etc.
   • Sectors: Food & beverage, consumer goods, healthcare, industrial.

2. Paper & Paperboard (including Corrugated):

   • Why Widely Used:
     • Cost-Effective: Especially for secondary and tertiary (shipping) packaging.
     • Printability: Excellent surface for branding and information.
     • Lightweight: Contributes to lower shipping costs.
     • Recyclability & Biodegradability: Generally good environmental profile if sourced sustainably and not heavily coated with plastics/foils.
     • Structural Strength (Corrugated): Ideal for shipping boxes.
   • Sectors: E-commerce, food & beverage (cereal boxes, drink cartons), electronics, cosmetics (secondary boxes), pharmaceuticals (secondary boxes).

3. Metal (Steel & Aluminum):

   • Why Widely Used:
     • Strength & Barrier: Unsurpassed for many applications requiring robust protection and long shelf life (e.g., canned foods, beverages, aerosols).
     • Recyclability: High recycling rates and can be recycled repeatedly.
   • Sectors: Food & beverage (cans), aerosols, industrial chemicals.

4. Glass:

   • Why Widely Used:
     • Inertness & Purity: Ideal for products where taste, odor, or chemical integrity is paramount (e.g., premium beverages, perfumes, pharmaceuticals).
     • Premium Perception: Conveys quality and luxury.
     • Recyclability: Infinitely recyclable.
   • Sectors: Beverage (beer, wine, spirits), food (jars), pharmaceuticals, cosmetics.

While plastics and paper/paperboard often lead in overall volume, the "most used" can also be viewed by specific segments. For instance, in the beverage can industry, aluminum is dominant. In luxury perfumes, glass is king.

In the pharmaceutical sector, plastics and paper/paperboard (for secondary packaging) are very heavily used, with glass and aluminum playing critical roles for specific dosage forms and protection needs. At ShineTop, while our core is cosmetics, our expertise in producing high-quality glass, plastic, and paperboard packaging means we understand the fundamental properties that make these materials suitable for a wide range of demanding applications.

Conclusion

Pharmaceutical packaging relies on a carefully selected range of materials, including specialized grades of glass, plastics, and metals like aluminum, to ensure drug safety, stability, and efficacy. While plastics and paper/paperboard are the most voluminous packaging materials globally, each material type plays a crucial role based on its unique properties and the specific demands of the product it encases, with pharmaceuticals requiring the highest standards of quality and compliance.