Choosing Foil Thickness in Pharma Packaging

Selecting the right foil thickness is one of the most important decisions in pharmaceutical packaging. It directly impacts product barrier, forming behavior, sealing reliability, and overall pack durability. While aluminium is naturally an excellent barrier material, the thickness determines how it performs during forming and sealing.

Why thickness matters

Foil thickness affects several critical parameters:

• Barrier performance against moisture, oxygen and light
• Formability during blister forming
• Pinhole resistance for high-shelf-life drugs
• Seal integrity during high-speed operations
• Print & lacquer compatibility

Common foil thicknesses

Thickness (µm)	Use Case	Advantages
20–22 µm	Standard blister packs	Cost-effective, good forming
25 µm	High-barrier pharma	Better pinhole resistance
30 µm	Deep cavities & medical devices	Maximum strength & barrier

Formability vs barrier

Thinner foils (20–22 µm) are easier to form but prone to pinholes. Thicker foils (25–30 µm) have stronger barrier properties but need higher forming force.

Impact of coatings

Heat-seal lacquers and primers influence the selection of thickness because coatings may affect flexibility or sealing temperature.

• HSL (Heat Seal Lacquer)
• Primer + overprint varnish
• Protective coatings

Machinability factors

• High-speed blistering lines require stable temper (H18/H19)
• Uniform thickness tolerance improves print registration
• Smooth foil surface reduces print defects

When to choose thicker foil

• Deep blister cavities
• Highly sensitive drug formulations
• Export packs requiring long shelf life
• High mechanical load during transport

Conclusion

Choosing foil thickness is a balance between barrier needs, forming complexity, sealing behavior, and cost-effectiveness. With the right specification, you ensure product safety and production efficiency.