Alu Alu Blister: Is This The Best Choice For Your Product?

Blister Packs

The packaging industry is currently witnessing a massive evolution. While traditional packaging methods have continued to thrive, alu alu blister is currently taking the industry by storm. 

With everyone looking out for the best alu alu blister packaging product out there, we thought to shed some light on what this innovation is and why it has become especially so popular. Plus, you get to decide whether it’s something you want to use or not. 

What Is Alu Alu Blister?


Alu Alu blister is one of the newest and already among the most popular forms of packaging being used in the pharmaceutical industry. Most manufacturers use it to protect things like capsules and tablets, and it does well to protect these items from any form of external damage. 

Interestingly, the name “Alu Alu” actually refers to the combination of materials that are used for this blister packaging. Alu Alu blister comes with three different layers, all making use of materials such as aluminum foil and polyvinyl chloride. With this combination, the packaging offers a nice protective shield against materials across the board. 

With alu alu blister, you have a packaging product with excellent barrier properties. It ensures that your pharmaceutical product remains stable and structurally sound, and it is especially effective when protecting medications that are sensitive to things like oxygen, light, and moisture. And as you can imagine, it goes a long way in ensuring that your medications can last longer. 

How Alu Alu Blister Looks 

Because the pharmaceutical industry is really big on efficiency and reliability, Alu Alu provides probably the best blister foil packaging available. But, how does it do that?

Layers of Alu Alu Blister

To begin with, let’s take a look at the composition of alu alu blister and how this unique build allows it to provide a suitable foil against external materials. 

Generally, this blister foil packaging option comes with the following layers: 

The First Bottom Layer

This section of the blister is usually made of aluminum foil. The foil provides the first barrier against things like oxygen and moisture, as well as external elements that might threaten the overall integrity of the pharmaceutical product. And considering that its thickness is also excellent, the benefits are pretty encompassing. 

Now, we should mention that you can find aluminum foil of different thickness ratings. This difference will mostly be based on your specific requirements and the process that goes into packaging the medication.  

A Barrier Layer In The Middle

Next, we have the middle layer, which usually comes made with a barrier material. As we said earlier, polyvinyl chloride or a similar polymer is usually applied here. Most manufacturers tend to prefer PVC because it is strong and transparent. Plus, processing it in blister machines tends to be very easy. 

Overall, this layer focuses on providing additional protection for your meds. It ensures that no external factors can compromise the product and its stability, and as you can imagine, this is very important.  

The Final Outer Layer

Then, we have a layer on the outer part of the packaging. This layer is very similar to the bottom layer in the sense that it is also made out of aluminum foil. With it, the blister’s barrier properties are much better, and the medication remains protected from oxygen and moisture exposure. 

Combined with the bottom layer, this one forms a strong and reliable structure that ensures the medication remains firmly enclosed. And, as you can imagine, it ensures that the drug’s integrity doesn’t degrade at all.  

Additional Layers Of Adhesive 

As part of the manufacturing process for alu alu blisters, manufacturers also add adhesive layers to bond the different components. These layers usually stand between the aluminum foil and the PVC, and you get some additional adhesive between the PVC and the second aluminum layer. 

Protection from environmental factors is the name of the game when it comes to alu alu blister packaging. However, it also goes a long way in ensuring that your medication is easy to manage and handle, so you can easily take it with you. 

How Alu Alu Blister Is Made


So we know the makeup of the alu alu blister. Now, let’s examine the process that goes into making it and how manufacturers manage to come up with this innovation:

The Initial Material Preparation 

Before anything, manufacturers start by preparing the different materials that will be in the blister packaging. This step includes material preparation and forming, as well as sealing. Aluminium foil rolls are unwound and properly cut, so you can achieve the right width levels. 

At the same time, you take rolls of PVC film and other suitable barrier materials. Unwind them, then cut them to fit the right dimensions. 

Form Both Materials Up Ideally 

Next, you take the  PVC and aluminum foil and feed them into the blister-forming machine. The machine will apply heat and pressure, using both to form cavities or pockets within the PVC film. From there, you’re able to create a mold for the capsules or tablets – whichever you choose. 

Next, You Fill Them Up 

Take the blisters you’ve formed and move them to the filling station, where you place the capsules or tablets into each cavity. From there, the top aluminum foil layer is applied to the PVC film, allowing you to completely cover the filled blisters. 

Seal Your Packaging Once And For All 

To seal everything up, you apply heat and pressure to the layers, allowing them to properly bond. Remember that there’s an adhesive layer between the middle layer and both the top and bottom layers. This adhesive is what will make bonding possible, and it will significantly improve the speed with which you’re able to get things done. 

At the end of the day, you get a blister pack that’s been properly sealed, with your capsule or tablet being properly enclosed inside. 

Let Your Product Cool Off

In some cases, you might need to put the blisters through a cooling process to ensure that your packaging is solid and your layers are aligned with each other within the form. 

Cut Everything To Size

You then take your blister strip and cut it into individual blister packs with the right sizing. This makes it much easier for you to package and send it over. 

Check What You Have One More Time

When it comes to pharmaceuticals, quality control is one of the most important things to always keep in mind. So, while you might be confident in what you’ve done, it doesn’t hurt to go over it one more time to make sure you’re set. 

From weight checks to visual inspections and more, make sure to look through everything to make sure that you have the right stuff. 

Once you’re set, package your meds and send them for distribution!

At the end of the day, different manufacturers have their process of making alu alu blister packaging. As long as you follow these steps, you should be more than fine. 

Advantages of Alu Alu Blister Packaging

Alu Alu blister packaging has been a revolution in the pharmaceutical space. Thanks to this packaging form, drug manufacturers can now confidently do their work without worrying about things like pharmaceutical contamination

But, what are the particular benefits that this packaging form gives? 

A Barrier Against Contaminants

The first and most significant benefit of alu alu blister foil packaging is that it offers a secure and reliable barrier that protects your medications from external contaminants like light, moisture, and oxygen. With this, you can rest assured that your drugs will remain efficient – especially if they’re sensitive to the environment. 

Long Functional Life For Your Meds

Alu alu blister foil packaging also ensures that your drugs will last as long as possible. By protecting them from degradation, it maintains their operational life as much as possible. 

Tamper Resistance For Optimal Security

Another major benefit of this foil blister packaging is that it is tamper-resistant. As such, it provides a sealed and secure packaging option that maintains the overall integrity of your products. 

For preventing tampering and unauthorized access, you can imagine that this is very important indeed. 

You Can Still Brand Your Drugs

The outer layer of alu alu foil blister packaging is a printable material that allows you to add your brand, print things like product information, and more. So, products can easily be discerned, and you can also enjoy access to proper branding and printing services. 

Holding Your Product’s Dimensions

Alu Alu packaging is built under cold conditions. With this, you get a packaging option that is both detailed and intricate in the way it works. As a result, your package will be able to closely conform to the shape of the product. 

The benefit of this is that you get even better protection for your medications. And because alu alu packaging is rigid, you can rest assured that it will protect all of the contents of your medications as they are being transported.

You Can Prevent Kids From Accessing

One of the major regulatory requirements for anyone looking to make drugs is that they be kept far from children. With alu alu packaging, you can create a medication packaging system that allows you to prevent child access. 

If your drugs pose any possible harm to kids, then you can imagine just how important this will be for you. 

Passing Down The Benefits Of Aluminum Foil

We should also note the fact that aluminum foil is the primary material for alu alu blister foil packaging. The material is known to be light and resistant to corrosion. Plus, aluminum offers an opaque barrier to light, which keeps light-sensitive medications safe. 

You Won’t Have Any Handling Issues

Blister packs made of this material are built to easily be dispensed and handled. Whether you’re a patient or a healthcare worker, you can rest assured that this blister packaging will be very easy to handle and move from one point to the other. 

How Alu Alu Blister Is Used In The Pharmaceutical Industry


The pharmaceutical industry is one place where a focus on quality and reliability will need to be maintained. So, because alu alu blister foil packaging is so impressive, you can imagine how much pharma companies want to make use of it. 

But, what are the aspects where this packaging form comes in handy?

Packaging The Main Drugs Themselves 

Easily the most significant function comes in its ability to improve the packaging for medications and drugs. With it, you get a tamper-resistant and reliable foil that stands against things like moisture, light, oxygen, and much more.

Keeping OTC Drugs Fresh 

We all know over-the-counter (OTC) drugs, which are mostly sold without doctors’ prescriptions. With alu alu packaging, you get a packaging option that allows you to protect these drugs while they are awaiting delivery. 

Strengthening Nutraceuticals In Transit

Vitamins, herbal formulations, dietary supplements, and other nutraceuticals need to be in top shape. And for many of these products, it might take a while for them to be delivered. As they await transportation and delivery, alu alu packaging can ensure that their quality remains the same. 

You Can Find It With Cosmetics Too

Another impressive benefit of alu alu blister foil packaging is that it helps with cosmeceuticals. These are products that combine the benefits of cosmetics and everyday drugs, and they use alu alu packaging to ensure that they remain reliable and effective. Their ingredients can be quite sensitive, so the last thing you want is for them to be exposed to light and other external contaminants. 

Maintaining The Quality Of Diagnostic Kits

We can see alu alu packaging being applied in packaging diagnostic kits and devices to ensure that all sensitive reagents are properly protected. And, with alu alu packaging covering the kits, you can rest assured that all test results they provide will be as accurate as possible. 

Protecting Medical Devices From The Elements 

Several medical devices need to also be protected from environmental factors to ensure that their use is unadulterated. With aluminum foil for blister packaging, you can cover these devices as they are being transported to make sure that the elements don’t affect them at all. 

Should You Use Alu Alu Packaging For Your Products?

white tabs

So we’ve pointed out all of the benefits that aluminum foil for blister packaging offers. Now, let’s look into some of the drawbacks that this packaging option has and a few things you might want to keep in mind if you hope to make use of it. 

It Can Be A Bit Pricey

When you consider the benefits that alu alu blister foil packaging offers, it should come as no surprise that it can be a bit expensive. But, have no fear – the benefits of this packaging option make it especially worth the price tag. 

Recycling Isn’t A Breeze

Sure, aluminum itself is recyclable. But, the process of recycling alu alu packaging isn’t necessarily as easy as you might think. And if you’re looking to achieve a high recycling rate, you might find that to be a bit of a challenge. 

You Won’t Get Much Flexibility

The fact that alu alu packaging is rigid is one of its main benefits. But, this rigidity can be a bit of a double-edged sword as well, as it makes the material significantly less flexible overall. When you’re trying to adapt to specific packaging designs, you might find this to be a bit of an issue. 

Note Its Impact On The Environment

The fact that aluminum can be recycled is pretty good. But, we should also point out the fact that extracting and processing the material can still have an impact on the environment. Considering that every manufacturer is now trying to cut their impact on the environment as much as possible, you might find it a bit challenging when trying to work with alu alu blister foil packaging. 

Transparency Is Also A Barrier

With aluminum being an opaque material, the transparency of alu alu blister foil packaging isn’t so great. If you need to inspect the meds visually, then you might find some difficulty.    


At the end of the day, pharmaceutical manufacturers are looking for the best products that can improve their processes as much as possible. And alu alu blister packaging easily helps you to achieve this. 

If you’d like to learn more about this packaging innovation, feel free to reach out to us at Sainty Tec for more information.

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