The “Cold Aluminium Armour” Guarding Every Tablet: An In-Depth Look at Alu-Alu Base Foil

Introduction: A Familiar Yet Invisible Guardian

We’ve all pushed a tablet out of those silver blister packs before. But have you ever wondered what really shields each pill from moisture, light, and oxygen? At HEALTHPLAST, we call it the “cold aluminium armour” — better known as Alu-Alu base foil or cold form aluminium foil.

For us in the pharmaceutical packaging industry, this material isn’t just shiny wrapping; it’s an invisible guardian ensuring patient safety and product stability.

What is Cold Form Aluminium Foil (Alu-Alu Base Foil)?

In simple terms, Alu-Alu base foil is a multi-layer laminate film used in pharmaceutical blister packaging. Unlike traditional PVC blister films that need heat to shape, this foil can be cold-formed into cavities at room temperature.

That single property makes it the go-to choice for sensitive medicines that degrade easily under heat, humidity, or light.

The Structure of Alu-Alu Base Foil

From our production experience, the “premium configuration” looks like this: OPA 25μm / AL 45μm / PVC 60μm.

OPA (Oriented Polyamide) – This is the armour’s outer shield. It adds toughness, puncture resistance, and excellent printability for branding.

AL (Aluminium Foil) – The true soul of cold form foil. At 45μm thickness, it delivers near-total barrier protection against water vapour, oxygen, and light.

PVC Layer – This inner layer makes sealing possible. It ensures strong heat-sealing with lidding foils while keeping push-through easy for patients.

When combined, these layers create a blister pack that protects like no other.

Why Do We Recommend cold form aluminium （Alu-Alu Foil）?

1. Total Barrier Protection

We’ve seen how humidity or oxygen can destroy a product’s stability. With cold form aluminium foil, the WVTR and OTR are practically zero, meaning your tablets stay potent until the very end of their shelf life.

2. Heat-Free Forming

Because it’s formed cold, there’s no risk of heat damaging active ingredients — a critical point for heat-sensitive medicines.

3. Longer Shelf Life & Fewer Complaints

In one project with a hypoglycaemic drug manufacturer, the product showed instability with standard PVC blisters. After switching to our Alu-Alu foil, stability data not only met the required standards but also cut market complaints significantly.

4. Premium Patient Experience

The metallic look conveys safety and quality. At the same time, the blister maintains easy push-through convenience for patients.

Where Do We See cold form aluminium （Alu-Alu Foil） in Action?

From our global partners, we’ve supplied Alu-Alu foils for:

Moisture-sensitive antibiotics and probiotics

Effervescent tablets

Hormonal medicines

Oncology drugs that demand high barrier packaging

Premium nutraceuticals and probiotic supplements

Even in traditional Chinese medicine extracts, this foil has proven its worth.

Is Cold Form Aluminium Worth the Cost?

Yes, it costs more than PVC or PVDC films — but in our view, it’s not a cost, it’s insurance.

Choosing Alu-Alu base foil means fewer stability failures, longer shelf life, better compliance, and stronger brand reputation. For companies who truly put quality and patient safety first, this material is an investment with long-term returns.

Conclusion: Choosing the Future of Your Product

To us at HEALTHPLAST, cold form aluminium foil is far more than packaging. It’s a silent partner that guards every tablet until it reaches the patient.

If you are evaluating your next pharmaceutical packaging solution, consider whether Alu-Alu base foil might be your product’s “invisible guardian.”
Contact us today to request a technical sample or discuss your project needs.