Aptar integrates Activ Film technology into blister packaging to create a protective microenvironment for dry powder inhalers

Packaging technology provides stability support for inhaled formulations. Aptar’s Activ Film technology has been integrated into blister packaging to protect inhalation therapy drugs and support their stability. This technology is aimed at the packaging needs of dry powder inhalers, by creating a protective microenvironment inside the packaging to help maintain the stability of the drug formulation. Dry powder inhalers are a form of administration that is sensitive to moisture and oxygen. Their blister packaging not only provides physical protection, but also needs to control the microenvironment inside the packaging during storage and transportation. Aptar has integrated Activ Film technology directly into the blister packaging structure, which means that the packaging itself has environmental regulation capabilities, rather than relying on additional desiccants or independent packaging components.

Significance for the polymer additive industry

From the perspective of materials and formulations, the core of this type of functional packaging solution lies in the film material’s ability to block and adsorb gases and moisture.

. In the field of polymer additives, antioxidants, light stabilizers, and UV absorbers are often used to extend the lifespan of polymer materials during processing and use, while functional masterbatch and maleic anhydride grafted wax can be used to improve the compatibility and dispersibility between fillers, additives, and resin matrices. When packaging requires long-term stable barrier performance, the selection and ratio of polymer additives will directly affect the mechanical strength, sealing performance, and aging behavior of the film. The integration of Activ Film technology into blister packaging also prompts polymer additive suppliers to pay attention to the medical and pharmaceutical packaging niche. Compared with ordinary consumer product packaging, inhaler foam covers require higher material cleanliness, mobility, and batch consistency. The selection of functional masterbatch carriers and the anhydride content of maleic anhydride grafted wax may affect the compatibility of the final packaging with the drug. The addition strategy of antioxidants and light stabilizers in such applications requires ensuring the stability of polymer processing while avoiding interference with the drug microenvironment.

Inspiration from application cases

Aptar did not disclose the specific chemical composition, barrier indicators, or clinical data of Activ Film in the source.

. But this case shows that packaging companies are transferring the active protection function from independent desiccant units to the packaging film itself, which poses new formulation design requirements for the polymer additive industry: how to achieve barrier, adsorption, and processing stability simultaneously in the film or masterbatch system without introducing migration substances that may affect the quality of inhaled formulations. For polymer additive companies, dry powder inhaler blister packaging can be seen as a potential application direction for functional masterbatch and polymer additives. UV absorbers and light stabilizers can help packaging materials maintain their performance under sterilization or storage light conditions, while antioxidants can help inhibit thermal oxidative degradation during processing. Maleic anhydride grafted wax can be used as a compatibilizer to adjust the dispersion of polar additives in polyolefin matrices, thereby affecting the uniformity and barrier consistency of the film. Overall, Aptar’s trend of integrating Activ Film into blister packaging reflects the increasing demand for material functionalization and microenvironment control in medical packaging. If polymer additives and functional masterbatch suppliers wish to enter this field, they need to conduct formula and process validation around low migration, high cleanliness, and batch stability.

Information source:Packaging Creates Protective Microenvironment for Dry Powder Inhalers， Organized by Herun Chemical.