Solvay unveils low-carbon coating for pharmaceutical blister films

03 Oct 2023 --- Solvay has launched Diofan Ultra736, a polyvinylidene chloride (PVDC) coating solution boasting an “ultra-high water vapor barrier with excellent thermoformability.” Designed for the pharmaceutical industry, Solvay’s Diofan Ultra736 is said to reduce carbon footprint by enabling thinner and lighter blister films compared to conventional applications.

The aqueous dispersion coating, being fluorine-free, complies with pharmaceutical regulations for direct contact.

“Consumers and legislators are requesting increased efforts related to carbon footprint reduction from the packaging industry, and one of the most effective means to this end is to reduce the size and weight of packaging products,” says Federico Baruffi, global marketing manager for Packaging at Solvay Specialty Polymers. Diofan Ultra736 is a PVDC coating solution that offers a combination of ultra-high water vapor barrier properties at reduced coating thickness.

“Our new Diofan Ultra736 coating solution can help packaging film manufacturers achieve superior barrier properties with thinner structures, leading to a significant carbon footprint reduction of the blister film.”

Carbon and layer reductions
Solvay’s Diofan PVDC coatings are employed in pharmaceutical blister packaging to safeguard sensitive solid-dose medications. Applicable on plastic and paper-based substrates, Diofan is also targeted at packaging delicate foods and various consumer goods due to its water vapor and oxygen barrier properties. 

Diofan Ultra736 offers a higher water vapor barrier than previously, without compromising the oxygen barrier, chemical resistance or transparency. 

“Diofan Ultra736 PVDC coating was custom engineered to maximize the water vapor barrier,” details Solvay.

Moreover, the PVDC coating solution boasts thermoformability, allowing manufacturers to create smaller pack sizes with increased pill density compared to existing alternatives. “Thanks to its ultra-high barrier performance, Diofan Ultra736 allows the reduction of the coating thickness compared to incumbent mid- to high-barrier PVDC coatings, without impacting functionality,” says Solvay.

For Duplex barrier structures, Diofan Ultra736 permits a reduction in base coat layers by half, while maintaining the same level of water vapor barrier. According to the company, the innovation could decrease the overall carbon footprint of final blister film structures by up to 13%.

Edited by Radhika Sikaria