For decades, plastic blister packs have been the standard for pharmaceutical packaging. They protect medicines from moisture and contamination, but they also create a major environmental problem. Most blister packs are made from a mix of plastic and aluminum that is difficult to recycle, leading to millions of tonnes of medical packaging waste each year. By 2026, the pharmaceutical industry is actively shifting toward circular packaging—packaging designed to be reused, recycled, or safely composted. Paper-based and mono-material solutions now deliver child resistance and recyclability without compromising drug stability.
The Problem with Plastic Blisters
Traditional PVC-PVDC blisters dominate pharma due to their barrier properties but contribute 30-40% of packaging waste, resisting recycling due to multi-layer lamination. These contribute to Scope 3 emissions, clashing with EU PPWR mandates effective 2026 requiring 40% recycled content.Mixed plastics end in incineration, undermining ESG goals.
What is changing?
Pharma companies replace traditional materials with:
Recyclable mono-material blister packs (made from a single type of plastic ,such as PET or PP )
Bio-based plastics derived from renewable sources like sugarcane or corn starch
Paper-based blister alternatives with protective coatings instead of plastic films
These innovations maintain drug safety while reducing environmental impact.
Real-world example
A strong example is Bayer’s launch of one‑material PET blister packaging for its Aleve products, developed in partnership with Liveo Research. This new recyclable PET blister pack significantly improves the environmental footprint by eliminating polyvinyl chloride (PVC) and reducing the carbon impact of packaging by about 38 % per unit compared to traditional multi‑material blisters.
Other industry innovators are also exploring circular design concepts. For instance, SCHOTT Pharma and partners have developed blister‑free secondary packaging for prefilled syringes that uses mono‑material cardboard for protection, reducing plastic waste and improving recycling potential across the value chain.
Circular Innovations Driving Change
Pharma companies are increasingly adopting mono-material blister packs made from recyclable polymers such as PET and PP to replace traditional plastic-aluminum composites, making packaging easier to recycle while maintaining drug protection. At the same time, SCHOTT Pharma is reducing the carbon footprint of injectable packaging by producing low-carbon pharmaceutical glass using electrified melting and renewable energy, cutting CO₂ emissions by up to 50%. Reusable transport carriers and digital printing further reduce material use and packaging waste across the value chain.
Why this matters
Circular packaging helps pharma companies:
Lower carbon footprint through lightweight designs and recyclable materials.
Comply with regulatory frameworks like the EU Packaging and Packaging Waste Regulation (PPWR) and Corporate Sustainability Reporting Directive (CSRD).
Build trust with eco‑conscious consumers, strengthening brand loyalty.
Path Forward
Pharma leaders are adopting circularity through supplier sustainability audits, lifecycle assessments (LCAs), and design‑for‑recycling standards. Integrating these practices not only helps companies meet regulatory mandates and ESG goals, but also creates competitive advantage by demonstrating leadership in sustainable innovation.
The shift from plastic blisters to circular packaging is no longer optional — by 2026, sustainable packaging strategies will be integral to how pharmaceutical companies balance patient safety, operational efficiency, and environmental responsibility.
PharmaX Next Conference 2026
The move toward sustainable and circular packaging will be a key discussion point at PharmaX Next Conference 2026 in Madrid, where industry leaders, innovators, and researchers will explore how digital transformation, AI, and sustainability are reshaping pharmaceutical operations. With sessions on green manufacturing, ESG in pharma, and cutting-edge packaging technologies, the conference provides a platform to share best practices and showcase real-world solutions like Bayer’s paper-based blister packs. For professionals looking to stay ahead in the rapidly evolving pharmaceutical landscape, understanding and adopting circular packaging strategies will be essential.
Reference
EY-Redefining pharmaceutical packaging for a sustainable future
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