Developed as part of the VinylPlus® PharmPack project, this study explores a dissolution-based recycling process for pharmaceutical blister packaging made from multilayer materials such as PVC, PVDC and aluminium. By selectively dissolving the PVC layer, the researchers were able to separate and recover high-purity recycled PVC from complex composite packaging.
The process was successfully scaled from laboratory to small-technical scale and achieved a PVC recovery yield of 47%. Material testing confirmed that the recovered PVC retained its chemical integrity, with minimal residual solvent and no significant degradation.
The recycled PVC was then incorporated into pharmaceutical film formulations and tested in thermoforming trials. Films containing recycled PVC showed comparable mechanical and thermal performance to virgin PVC films, including reliable sealing and leak-proof blister production.
The study demonstrates that dissolution-based recycling could offer a promising route for circular use of PVC in pharmaceutical blister packaging. Future work will focus on pilot-scale validation, as well as economic and environmental assessment.
