Sterile barrier systems and recyclable blister packaging solutions Polypropylene Blisters and Valid System Films 

Südpack Medica offers a range of coordinated base and lid films as well as pouch systems under the MedGuard brand. Complemented by the PP-based PharmaGuard blister concept, recyclable alternatives to aluminum-PET combinations are available. Test series conducted at the company’s in-house technical center demonstrate how sealing parameters can be adjusted on existing equipment.

Südpack Medica is expanding its range of packaging systems for the medical technology, pharmaceutical, and life sciences industries. Under the brand name Medguard, the company offers a comprehensive selection of flexible and rigid film structures, bag and pouch solutions, and matching lid materials. The focus is on providing validated sterile barrier systems in accordance with ISO 11607, which are designed to ensure high reproducibility of the sealing processes. A digital product navigator helps processors select suitable material combinations based on specific requirement profiles and common sterilization methods such as steam, ethylene oxide (EtO), or gamma irradiation. 

Single-material alternatives for solid oral dosage forms

In addition to traditional film structures, the portfolio includes the Pharmaguard blister concept, which was developed specifically for packaging solid oral dosage forms. The polypropylene (PP)-based blister films are free of phthalates, vinyl, PFAS, and halogens. Due to their high PP content, the films can be incorporated into existing polypropylene recycling streams, which significantly reduces their environmental impact compared to conventional composite materials made of aluminum and PET. The CO₂ reduction has been verified by a life cycle assessment (LCA) in accordance with ISO 14040/44. Despite the switch to monomaterials, the films offer a high water vapor barrier as well as defined puncture resistance when dispensing medications. 

Cleanroom Manufacturing and Optimization of Sealing Parameters

To meet the cleanliness and sterility standards required by the healthcare industry, special lid materials and pouch systems are manufactured in certified cleanroom environments. To ensure reliable processing, the manufacturer collaborates directly with producers of medical-grade paper and manufacturers of packaging machinery. In-house application engineers analyze the mechanical, thermal, and functional properties of the films in the company’s own laboratories. Based on this, the sealing performance and opening behavior can be specifically tailored to the mechanical and thermal requirements of the respective packaging system. 

Process Validation and Determination of the Sealing Windows in the Pilot Plant

Before new packaging concepts are scaled up for commercial production, processors have access to practical testing facilities at the Ochsenhausen pilot plant. There, sealing tests are conducted using Medguard and Pharmaguard films in combination with various lid materials under real production conditions. These test series enable the precise determination of sealing windows, peel forces, and overall process robustness. If necessary, the technical center coordinates joint optimization tests between the user and the respective machine supplier to minimize the time required to introduce new packaging materials on existing equipment. (mg)