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2018
PERFORMANCE OF ALUMINIUM BASED PACKAGING MATERIALS RELATED TO THE STRUCTUREby Dr. E. Pasbrig, GM Development and TechnologyACG Films & Foils
INFLUENCE OF ALUMINIUM THICKNESS OF CFF AND PUSH THROUGH FOIL TO EFFICIENCY AND COST
Cold form laminate in India normally has aluminium thickness of 50 µm. Internationally,
45 µm is used for packaging of standard products. If a higher dent resistant of cavity is
needed, the thickness of aluminium will be 60 µm.
Di�erence of 5 µm in thickness does not provide a better dent resistant, as shown in
next table.
Cold form laminate in India normally has aluminium thickness of 50 µm. Internationally,
45 µm is used for packaging of standard products. If a higher dent resistant of cavity is
needed, the thickness of aluminium will be 60 µm.
Di�erence of 5 µm in thickness does not provide a better dent resistant, as shown in
next table. Formability of the laminate with 50 µm aluminium is not increased
compared to the standard laminate with 45 µm Al. Use of laminate with 60 mm
aluminium provides a slightly better formability and more consistent forming results
related to pinholes (higher cost).
Reduction of aluminium thickness by 5 µm for a cold form blister with dimension of
120 x 55 mm results in 18 kg material saving for packing 2 Lakh of blister.
oPA-Al-PVC
40 cycle/min, blister 120 x 55 mm
Aluminium thickness (µm)
1 reel (20 kg) in m2
45 50
84.4 79.8
422 399
844 798
313 331
18
6311
Running meter (width 200 mm)
2 blister/cycle
2 lac blister (1320 sqm) (kg)
Saving (kg)
Approximately Saving (INR)
CFF Sti�ness(Nmm)
1.13
1.14
2.12
25-45-60
25-50-60
25-60-60
Cycle per reel (14 kg) Running time per reel
Possible savings over a year, depending how many shifts per day are done, are in the
range of INR 22 to 89 Lakh.
The example is showing, that CFF with 50 µm does not have an advantage in
performance, needed higher amount of material by area and more frequent changes of
reels during production.
For a production of blister (60 x 95 mm; 4 blister/cycle; 40 cycle/min; weight of
reel = 14 kg) switching from 25 to 20 µm, produces 7040 blisters more, with 20 µm foil.
In addition, time until reel needs to be changed is increased by 44 min.
LID FOIL, ALUMINIUM THICKNESS 25 µm AND 20 µm
Similar result we get for the change of 25 µm to 20 µm aluminium thickness for lid foil.
Beside the USA market, all other countries use a thickness of 20 µm, and Japan uses
even 3 µm less.
For aluminium foil produced in Europe, the maximum amount of pinholes per m2 with
0.5, respective 0.4 for 25 µm are similar and do not influence the barrier properties of
the sealed blister.
Savings of material for the lid foil, as mentioned in the following table, are up to 21.8%.
1 shift/day
kg INR (Lakh)
6552 22.3
13104 44.6
26208 89.2
2 shifts/day
4 shifts/day
CFF HSL Lacquer Weight Yield Saving
54.0 7 1 62.0 16.1 21.80%
67.5 7 1 75.5 13.2
Thickness (µm) 20 25
225.8 185.4
9956 8176
14 kg = m2
Cycle/14 kg
Thickness (µm) 20 25
249 205
44
Production time (min)
Di�erence (min)
Related to seal strength, heat resistance, abrasion of printing ink, there is no di�erence
between the 20 and 25 µm foil used for converting.
Burst pressure is increasing with the thickness of the foil. With this push through, force
is increasing too. It is di�cult to push a hart gelatine capsule through 25 µm foil
without denting/pressing the capsule.
REDUCTION OF PACKAGING MATERIAL - STRIP PACK – CFF – TROPICAL BLISTER
Moisture sensitive products packed in strip pack are as well protected as in CFF. If
sealing layer of CFF has to be identical as strip pack, LDPE or HDPE can be used. As
sealing layer of lid foil an extrusion coating of LDPE on 20 µm aluminium is used.
Comparison of strip pack and CFF highlights the main points as:
• more packaging material has to be used
• product is in direct contact with sealing roller (hard gelatine capsule can stick on PE)
and temperature sensitive products cannot be packed
Calculations to compare size of pack have shown, that with usage of CFF, 30% to 70%
reduction is possible, depending on product geometry. If tropical blister is used, further
saving is possible. Reduction in size is not identical with saving of cost. But if all points
are taken, every example shows savings:
• production time and output
• lower weight
• smaller folding carton
• more blister in shipper
• lower cost for logistics
These calculations come into play if a customer expresses an interest to switch from
strip pack to CFF or tropical blister.
LID PE
Sealing layer of lid foil (push through) for sealing to CFF with polyethylene (LDPE,
HDPE, CFF with desiccant) is produced by extrusion coating. To get su�cient
adhesion to the aluminium surface a primer (lacquer) is used between aluminium and
PE. Because of this sealing, the layer related to lid foil is double in thickness compared
with lacquer of 7 g/m2 where double amount of humidity and oxygen is migrating
through it into the cavity.
We were able to develop a push through foil with a lacquer in sealing to polyethylene
with 5 or 7 g/m2, depending on customer requests. Not only is the cost less, but more
importantly, the cross migration is reduced by 50%. This lid foil is on the market
already and replacing the material with extruded LDPE.
SUMMARY
• Use of CFF with aluminium of 50 µm compared with 45 µm does not have any
advantage related to performance; costis higher related to area.
• Switching of lid foil with 25 µm aluminium to 20 µm provides an advantage related to
cost and change time of a reel
• Change from strip pack to CFF can reduce pack size by 30 – 70%.
• Lid foil for sealing to polyethylene with a lacquer can replace the currently used lid
foil with LDPE extrusion coating. It provides cost advantage and better barrier
related to cross di�usion of a CFF blister.
• If barrier layer of thermo form films are on inner side barrier properties after forming
is increased by 11 – 15%.
• ACG Pharmapack is offering a unique service to the pharmaceutical industry related
to thermo forming, cold forming and sealing.
Related to seal strength, heat resistance, abrasion of printing ink, there is no di�erence
between the 20 and 25 µm foil used for converting.
Burst pressure is increasing with the thickness of the foil. With this push through, force
is increasing too. It is di�cult to push a hart gelatine capsule through 25 µm foil
without denting/pressing the capsule.
REDUCTION OF PACKAGING MATERIAL - STRIP PACK – CFF – TROPICAL BLISTER
Moisture sensitive products packed in strip pack are as well protected as in CFF. If
sealing layer of CFF has to be identical as strip pack, LDPE or HDPE can be used. As
sealing layer of lid foil an extrusion coating of LDPE on 20 µm aluminium is used.
Comparison of strip pack and CFF highlights the main points as:
• more packaging material has to be used
• product is in direct contact with sealing roller (hard gelatine capsule can stick on PE)
and temperature sensitive products cannot be packed
Calculations to compare size of pack have shown, that with usage of CFF, 30% to 70%
reduction is possible, depending on product geometry. If tropical blister is used, further
saving is possible. Reduction in size is not identical with saving of cost. But if all points
are taken, every example shows savings:
• production time and output
• lower weight
• smaller folding carton
• more blister in shipper
• lower cost for logistics
These calculations come into play if a customer expresses an interest to switch from
strip pack to CFF or tropical blister.
LID PE
Sealing layer of lid foil (push through) for sealing to CFF with polyethylene (LDPE,
HDPE, CFF with desiccant) is produced by extrusion coating. To get su�cient
adhesion to the aluminium surface a primer (lacquer) is used between aluminium and
PE. Because of this sealing, the layer related to lid foil is double in thickness compared
with lacquer of 7 g/m2 where double amount of humidity and oxygen is migrating
through it into the cavity.
We were able to develop a push through foil with a lacquer in sealing to polyethylene
with 5 or 7 g/m2, depending on customer requests. Not only is the cost less, but more
importantly, the cross migration is reduced by 50%. This lid foil is on the market
already and replacing the material with extruded LDPE.
SUMMARY
• Use of CFF with aluminium of 50 µm compared with 45 µm does not have any
advantage related to performance; costis higher related to area.
• Switching of lid foil with 25 µm aluminium to 20 µm provides an advantage related to
cost and change time of a reel
• Change from strip pack to CFF can reduce pack size by 30 – 70%.
• Lid foil for sealing to polyethylene with a lacquer can replace the currently used lid
foil with LDPE extrusion coating. It provides cost advantage and better barrier
related to cross di�usion of a CFF blister.
• If barrier layer of thermo form films are on inner side barrier properties after forming
is increased by 11 – 15%.
• ACG Pharmapack is offering a unique service to the pharmaceutical industry related
to thermo forming, cold forming and sealing.