Klöckner Pentaplast director: kpNext plastic blister pack answers recyclable pharma demands

27 Aug 2021 --- Klöckner Pentaplast (KP), an international manufacturer of high-barrier packaging solutions, is launching kpNext, marketed as the only recyclable PET blister completely compatible with pharmaceutical manufacturing form, fill and seal equipment. 

Speaking to PackagingInsights, KP’s director of marketing and communications, Jeff Cole, describes the challenges the company faced in producing the packs. 

“One of the biggest difficulties was trying to create a film that was both a Resin Identification Code (RIC) 1 recyclable solution and one that does not require the converter or pharmaceutical manufacturer to slow down or adjust their production lines to accommodate the new film,” he details.

RIC 1 materials can be disposed of in most curbside collection streams throughout the US. 

“Current pharmaceutical blister packaging is classified as RIC 7, produced from a multi-material structure, which is not recyclable and therefore is disposed of in a landfill or incinerated,” adds Daniel Stagnaro, head of technology. 

“Major pharmaceutical companies have been challenging blister manufacturers for a solution that is responsible and recyclable. KP has answered those challenges with kpNext.” 

Demand for more sustainable pharmaceutical packaging is on the rise.Turning blisters circular 
KP has a history of developing pharmaceutical blister packaging solutions, and kpNextׄ is its latest innovation in the space. Not only is kpNext the only PET film designed to be a recyclable blister package, but it does not come at the expense of the manufacturing process, asserts Cole. 

“There are many levels of complexity around producing a material that can be recycled where it does not cause issues at the recycling centers. Solving for those complexities can’t come at the expense of the pharmaceutical company in the form of slower line speeds. That is the real beauty of kpNext.” 

He adds that pharmaceutical companies and converters can use kpNext on their existing form, fill and seal lines with no loss of line speed or a need to retool. 

kpNext took three years’ worth of research and development to produce. Utilizing its kp i.center, an application development lab located in Virginia, US, kp scientists, chemists and technical teams worked to develop the technology. 

Mounting recyclable blister demand 
The demand for recyclable pharmaceutical packaging is rising, and kpNext is intended to answer those calls, says Cole. 

“For the most part, the RIC 1 stream is mainly for bottles. kpNext R1 is a jumping-off point to expand the types of materials that can be recycled that will not compromise the integrity of the recycled content or the processability of the recycling centers.” 

Related developments
Last month, US-based Keystone Folding Box reported a surge in demand for its line of child-resistant, paperboard-based blister packs from pharmaceutical companies in India. The sales spike for its Key-Pak portfolio comes amid new environmental sustainability legislation in India and increased demand for child-resistant pharmaceutical packaging in the US.

In January, TerraCycle launched the UK’s first recycling program specifically for blisters unsuitable for national recycling streams. 

In April, Amcor launched customer trials for a new mono-material, recyclable polyethylene blister pack in what it claimed was a “breakthrough” for pharmaceutical packaging. Branded AmSky, the packs are designed to eliminate PVC, which makes recycling difficult due to chlorine content. 

By Louis Gore-Langton 

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