Blister Packaging: Bayer Opts for Single-Material PP Polypropylene Replaces PVC/Aluminum Composite

Bayer is switching the packaging for Talcid to a recyclable, single-material PP blister pack. The system replaces traditional PVC/aluminum composites without compromising the water vapor barrier. The solution demonstrates how pharmaceutical safety and recyclability can be achieved using existing packaging equipment.

For decades, PVC and aluminum blister packs were considered the packaging standard in the pharmaceutical industry. Tried-and-true, reliable, and safe—but with a downside: They are difficult to recycle and contribute to massive amounts of packaging waste. But now Bayer is taking a step in a different direction: The company’s pharmaceutical division is launching Talcid, its medication for promoting digestive health, in new packaging. The rollout begins in Germany, with the goal of introducing the solution in other international markets.

PP monoblister packs instead of conventional PVC/aluminum laminates

Bayer is switching the primary packaging from conventional PVC/aluminum composite films to a polypropylene monoblister from Etimex Primary Packaging. The goal of this material change is to transition from composite structures that are difficult to separate to mechanically recyclable monomaterials while maintaining the protective function for the medication.

“Our PP mono packaging was developed specifically to meet the high standards of the pharmaceutical and medical device industries,” explains Martin Rank, Head of Sales & Marketing at Etimex Primary Packaging. “In all key characteristics, it is on par with conventional PVC/aluminum solutions,” Rank emphasizes.

Two components, one thermoplastic

The Purelay blister system consists of two complementary polypropylene-based components. The thermoformable base film, Purelay Pharm, is halogen-free, offers high transparency for visual inspection of the tablets, and provides the necessary water vapor barrier. The accompanying Purelay Lid top sheet ensures a tight seal during the sealing process while offering defined push-through properties for the user and can be custom-designed using printing techniques. 

“At the same time, monomaterials are characterized by a significantly better environmental footprint and full recyclability,” explains Martin Rank. “Etimex was a key partner in translating our commitment to sustainable packaging into a concrete solution for consumers,” says Christoph Kaminski, Packaging Sustainability Manager at Bayer.

Process Integration and CO₂ Reduction

During the conversion of the packaging lines, the processability of the PP films on existing blister packaging systems proved to be a key factor. The thermoplastic film combination is designed—in terms of its sealing parameters and forming properties—for seamless integration into established packaging processes. In addition to being recyclable within the PP recycling stream, the lower density of polypropylene compared to PVC and aluminum leads to a reduction in packaging weight and the resulting transportation CO₂ emissions.

“The new Talcid monoblister is a prime example of how collaboration can help reduce the complexity of packaging,” explains Christoph Kaminski. “In this way, we promote recyclability while maintaining the high quality and safety standards for consumer health products.”

Compliance with future recycling requirements

The use of PP monomaterials in the pharmaceutical sector is a response to stricter regulatory requirements for packaging waste and material recycling rates in the European market. By eliminating halogen-containing polymers such as PVC and aluminum cover films, this single-material solution simplifies sorting and material recycling within existing waste management systems.

“We are proud to have Bayer as a strong partner at our side, working with us to put sustainable packaging solutions into practice,” emphasizes Martin Rank. “This is another milestone on the path toward a more environmentally friendly consumer health industry.” (mg)