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Private Company
Recyclable high-barrier blister packaging
  • Background
  • What we're looking for
  • What we can offer you
  • Q&A
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Background

Over The Counter (OTC) unit dose products, such as tablets or capsules, often come in high barrier, mixed material blister packaging. These rely on complex, multi-layered materials that combine plastics and foils to deliver the high moisture and oxygen barrier properties required to protect the product. 

 

Since the mixed materials used are not easily separated or processed by most recycling systems, these packages are not recyclable through standard municipal waste streams. With growing demand for OTC products globally, there is a parallel rise in the volume of non-recyclable blister packaging entering the waste stream. 

 

There is a clear need to identify or develop high-barrier unit dose packaging alternatives that are both functional and recyclable, to reduce landfill waste and advance the broader goals of sustainable packaging.

What we're looking for

We are looking to identify medium, high and ultra-high barrier blister packaging solutions that are recycle-ready and/or recyclable as a complete format. Ideal solutions should reduce the use of virgin petroleum-based plastic compared to traditional blister packs and deliver lower overall carbon footprint.

A blister pack consists of a web and a lid and these two components are heat-sealed together to form the whole blister. The combination of web and lid materials should not prevent recyclability through commonly available collection and sorting systems.

Solutions of interest include:
  • Mono-material solutions
  • Aluminum-based blisters
  • High-barrier polymers/biopolymers
  • Recycled-content blister packaging
  • Coated paper-based blister systems
Our must-have requirements are:
  • Water vapor transmission rate (WVTR - g/m2/day) and oxygen transmission rate (OTR - cm3/m2/day) is between <0.1 and <0.005, in line with high or ultra-high barrier performance
  • Recycle-ready per RecyClass or the Association of Plastics Recyclers (APR)
  • Clear rationale or supporting evidence of compatibility with standard blister lines (for both web & lidding)
  • Delivers consistent, high-quality web-to-lid seal
Our nice-to-have's are:
  • Supports good-quality printing

  • Offers improved opening experience, such as lower push-through force or peelable lid

  • Contains recycled or bio-based content

Acceptable technology readiness levels (TRL):
Levels 4-9
What we can offer you
Eligible partnership models:
Sponsored researchCo-developmentSupply/purchaseLicensing
Benefits:
Sponsored Research
Funding is proposal-dependent, starting with a proof-of-concept project that has the potential for expansion based on results and opportunities. The funding range is from $25,000 to $100,000 for a six-month project.
Q&A with the company

The Q&A is now closed.

Sort by:
Q.
Would a fully compostable material be of interest?
1
A.
Compostable is less of a priority, however there are 2 conditions which may be appropriate for composting. Firstly, where it does not impact the recyclability of the packaging solution and secondly it must be home compostable, industrially compostable is not of interest.
Team Member, Reviewer, Private Company
September 19, 2025
Is this response helpful?
2
0
Q.
Is metallization allowed after applying the coating?
1
A.
If this does not impact the recyclability of the format and the manufacturing processes do not vary significantly from existing blister manufacturing (web & lidding process) then metallisation could be considered. Typically the web and lidding substrates are provided as separate reels of material, so if this would still be the case, then this process could be considered. This assumes that this process is essential to provide the required properties
Team Member, Reviewer, Private Company
August 11, 2025
Is this response helpful?
0
0
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