railings to provide your employees a safe work place

Packaging Pharmaceuticals With Aluminum Seals: A Look At The Differences Between Cold Forming And Thermoforming Blister Packs

Universal health greatly improved once medications for numerous deadly diseases were developed. Almost all diseases and medical conditions can now be treated with medicine, and the total nominal spending on medicines in the U.S. has now surpassed $329 billion each year. Oral medications are generally packaged in blister packs with an aluminum seal. If you own your own pharmacy, you can choose to package the tablet with one of the two following methods: cold forming or thermoforming.

A Better Look at Cold Forming Aluminum Seal Blister Packs

Cold forming aluminum seal blister packs are made entirely with aluminum seals and foils. These blister packs laminate an aluminum seal onto an aluminum base using a mold. The mold will create the indentation, or cavity, where the medication will sit in. Cold forming aluminum seal blister packs tend to be more expensive to manufacture thanks to higher material costs and slower production speeds; however, this method is still preferred by many pharmacies and manufacturers because the aluminum in the cold forming aluminum seal blister packs:

  • Acts as a barrier for moisture, light and oxygen. This prevents any external elements from affecting the pharmaceutical and reduces the risk for contamination of any kind.
  • Increases the expiration of the products. Since it is unlikely for the medicine to be disturbed after it has been packaged, the perfect preservation of the condition and property of the medicine will prevent it from losing its chemical integrity. 
  • Increased tamper resistance. It is easy to quickly tell whenever the packages have been tampered with or damaged. Resealing the packaging is not a possibility once it has been opened.

Further Insight Into Thermoforming Aluminum Seal Blister Packs

Cold forming aluminum seal blister packs rely on only aluminum seals to form the entire packaging. Thermoforming aluminum seal blister packs, on the other hand, incorporate plastic with the aluminum as well.  In this technique, the cavity where the medicine sits is constructed from clear, thermoformed plastic. The plastic is then placed on top of heating plates, which make it more pliable, and then an aluminum seal is the applied overtop.

Thermoforming aluminum seal blister packs are not as secure as cold forming aluminum seal blister packs because moisture and oxygen can still enter the packaging. The plastic also exposes the packaged medication to ultraviolet rays from light. Although thermoforming aluminum seal blister packs are not as foolproof and secure, they do offer some distinct benefits, which include:

  • Low cost. The use of thermoformed plastic instead of aluminum greatly reduces material costs. In addition, the production speeds for thermoforming aluminum seal blister packs are also faster. These blister packs are compatible with universal feeders, which are responsible for sweeping the medications into the cavities.
  • The ability to examine the packaged medication without having to open the package. The clear plastic makes it easy to check to make sure the right type of medication is given to patients.
  • Tamper resistance. Once again, it's easy to check for any tampering with thermoforming aluminum seal blister packs. The clear plastic allows patients to determine whether the medication was damaged and whether the packaging was opened.


Thermoforming and cold forming aluminum seal blister packs are among some of the most common packaging methods recommended for the pharmaceutical industry. These packaging options are portable and difficult to break. In addition, they provide an easy way for patients to keep track of the amount of pills they have taken. Aluminum is one of the better metals to work with when packaging medication. It's cost-efficient and also resistant to bacteria, fungi and other pathogenic microbes making it perfect for the medical industry. 

You can also check out sites like http://www.phoenixspecialty.com/ for more info.