Case study

Machinability of PVC-free blister packaging

  • Reading time 1 min

  1. Project objective

    Evaluate the machinability of alternative materials to PVC-based blister packaging, with the aim of improving recyclability while maintaining industrial performance.

  2. Year

    2024

  3. Lab/Division

    OPENLab site
    Ozzano (Bologna)
    IMA division/company involved
    IMA SAFE

Project overview

IMA SAFE tested several mono-material alternatives to PVC, including PP, PET, PE and paper-based solutions.
OPENLab analysed these materials to identify correlations between packaging performance and material structure.

In particular, PET demonstrated a high level of interchangeability with PVC in terms of machine setup, requiring minimal tuning when switching from PVC-based packaging.

OPENLab investigated sealing forces for PVC–Alu and PET–Alu combinations, as well as the mechanical properties of the formable materials, to better understand the observed behaviour.

Tensile Tests

Average Max Load (MPa) 

Average Maximum Elongation (%) 

Average Elastic Modulus (MPa)

PVC Formable

55 ± 1 

19 ± 3 

765 ± 43 

PET Formable

55 ± 5 

16 ± 4 

612 ± 8 

Key results

  • Validation of IMA SAFE machines’ ability to process a wide range of PVC-free blister packaging solutions.
  • Technical explanation of the limited adjustments required when transitioning from PVC to PET, based on comparable mechanical and sealing properties.