What Are the Disadvantages of PVDC in Pharmaceutical Packaging?

If you have ever held a blister pack in your hand, you’ve likely come across PVDC (Polyvinylidene Chloride) film. Known for its exceptional barrier against moisture, oxygen, and gas, PVDC has been a trusted material in pharmaceutical packaging for decades. PVDC also comes with limitations that manufacturers and procurement managers must weigh carefully. But just like every coin has two sides.

PVDC plays a vital role in extending product shelf life and protecting sensitive medicines, it is not always the perfect solution. Let’s explore the key disadvantages of PVDC that may influence your packaging decisions:

Environmental Concerns

PVDC is a chlorinated polymer, and during incineration, it can release harmful substances like hydrochloric acid and dioxins. This makes it less environmentally friendly compared to alternatives like PET or EVOH.

Increasing global regulations and sustainability initiatives are pushing companies to reduce reliance on chlorinated materials.

Processing Challenges

PVDC requires precise coating technology, which raises production complexity and cost.

Film uniformity and coating adhesion can be difficult to control, leading to potential quality consistency issues.

Cost Factor

Compared to standard PVC or PET, PVDC-coated films are generally more expensive due to the multi-layer lamination process.

For price-sensitive markets, this can become a barrier to large-scale adoption.

Limited Heat Resistance

PVDC films may deform or discolor under high temperatures, which restricts their compatibility with certain packaging processes.

Regulatory Pressure

Some regions are increasingly cautious about the use of chlorinated packaging. Companies exporting to Europe or environmentally strict markets may face compliance challenges.

Comparison: PVDC vs. PVC vs. PET in Pharmaceutical Packaging

 

 

Feature / Property	PVDC	PVC (Polyvinyl Chloride)	PET (Polyethylene Terephthalate)
Moisture & Oxygen Barrier	★★★★★ Excellent	★★ Moderate	★★★ Good
Cost	★★★ Relatively High	★ Low	★★ Medium
Environmental Impact	★ Low (chlorinated, harmful on burning)	★ Low (chlorinated, less sustainable)	★★★ Better (non-chlorinated, recyclable)
Heat Resistance	★★ Limited	★★★ Moderate	★★★★ High
Processing Complexity	★★★ Requires coating & lamination	★ Easy to process	★★ Requires precision in molding
Regulatory Pressure	High (restricted in some markets)	Moderate	Low (widely accepted, eco-friendlier)
Typical Application	High-barrier blister packs	Standard blister packs	Premium or eco-conscious packaging
Feature / Property	PVDC	PVC (Polyvinyl Chloride)	PET (Polyethylene Terephthalate)
Moisture & Oxygen Barrier	★★★★★ Excellent	★★ Moderate	★★★ Good

 

How to Use This Table for Decision-Making?

If barrier protection is your top priority → PVDC is still the strongest choice.

If cost efficiency is critical → PVC works for many standard medicines.

If you seek a balance of performance and sustainability → PET may be your better option.

Does this mean PVDC has no place in modern pharmaceutical packaging? Not at all. Despite its disadvantages, PVDC continues to be widely used where maximum barrier protection is required. However, it is important for manufacturers, especially pharmaceutical and healthcare companies, to evaluate whether the benefits outweigh the drawbacks in their specific applications.

This is also where exploring alternatives like PVC/PE/PVDC, PVC/PVDC, or PET/PVDC films becomes essential. Hybrid structures can balance barrier performance, cost, and sustainability.

At Healthplast, we specialize in customized pharmaceutical packaging films — from PVC rigid films to multi-layer PVDC-coated solutions. Whether you are looking for cost-effective protection or eco-conscious alternatives, our team can guide you toward the right material choice.

Contact us today at www.healthplast.com to discuss your packaging requirements.

 

FAQ: Disadvantages of PVDC in Pharmaceutical Packaging

1. Why is PVDC considered harmful to the environment?
   PVDC contains chlorine, and when incinerated, it can release hydrochloric acid and dioxins. These substances are harmful to both the environment and human health, which is why sustainability-focused markets are limiting its use.
2. Is PVDC more expensive than PVC or PET?
   Yes. PVDC-coated films involve a multi-layer lamination process, making them more costly compared to standard PVC or PET films. This can affect packaging budgets, especially in price-sensitive markets.
3. Does PVDC affect regulatory compliance?
   In some regions, particularly in Europe, chlorinated packaging materials like PVDC face stricter regulations. Pharmaceutical companies exporting to these markets must carefully evaluate compliance requirements.
4. What are the alternatives to PVDC?
   Alternatives include:

           PVC/PE/PVDC Film (balances barrier and cost)

           PET/PVDC Film (better sustainability and strength)

           Non-chlorinated films such as EVOH-based laminates for eco-conscious applications.

5. Should I stop using PVDC completely?
   Not necessarily. PVDC remains one of the best barrier materials in pharmaceutical packaging. The decision depends on your product’s sensitivity, shelf-life requirements, market regulations, and sustainability goals.