What is Alu-Alu Base Foil?

What is Alu-Alu Base Foil? A Comprehensive Guide for Pharmaceutical Packaging

Introduction

When it comes to high-barrier pharmaceutical packaging, Alu-Alu base foil is a game changer. Designed for the most sensitive medicines, it offers unmatched protection against moisture, oxygen, light, and contaminants. In the pharmaceutical world, where product stability directly affects patient safety, the choice of packaging material is as critical as the product itself.

At HEALTHPLAST, we specialize in providing pharmaceutical-grade Alu-Alu foils with precise technical specifications to meet stringent GMP and regulatory requirements.

1. Understanding the Structure of Alu-Alu Base Foil

Unlike traditional blister packaging that uses PVC or PVDC as the forming web, Alu-Alu base foil (also known as cold form foil) is a multi-layer laminate composed entirely of aluminum.
Typical structure:

OPA (Oriented Polyamide) layer – Improves mechanical strength, formability, and puncture resistance.

Aluminum core layer – Provides a complete barrier against moisture, oxygen, UV light, and gases.

PVC or other sealing layer – Ensures secure heat sealing to the lidding foil.

This all-aluminum structure creates a “total barrier” environment, making it ideal for packaging moisture-sensitive or light-sensitive medicines.

2. Why Choose Alu-Alu Base Foil?

2.1 Total Barrier Protection

Unlike PVC/PVDC film, Alu-Alu foil offers zero water vapor transmission rate (WVTR) and zero oxygen transmission rate (OTR), ensuring the drug maintains its potency until the end of its shelf life.

2.2 Extended Shelf Life

Pharmaceutical stability studies prove that products packaged in Alu-Alu foil maintain active ingredient integrity for significantly longer periods, especially in tropical or humid climates.

2.3 Tamper Evidence & Patient Safety

Its unique metallic appearance and non-transparent design provide visual assurance of product integrity.

2.4 High Formability

Cold forming allows for deep cavity shapes without compromising barrier properties, making it perfect for irregular tablet or capsule shapes.

3. Common Applications

Moisture-sensitive antibiotics and probiotics

Effervescent tablets

Hormonal medicines

High-value nutraceuticals

Light-sensitive oncology drugs

4. Key Technical Parameters to Consider

When sourcing Alu-Alu base foil, pay attention to:

Parameter	Typical Range	Importance
OPA Thickness	25–30 μm	Impacts formability
Aluminum Thickness	45–60 μm	Determines barrier strength
PVC Layer	60–100 μm	Affects sealing and stability
WVTR & OTR	0.0	Ensures total barrier
Forming Depth	Up to 12 mm	For large tablets/capsules

5. HEALTHPLAST Quality Advantages

Pharmaceutical-grade materials meeting US FDA, EU GMP standards

Custom thickness combinations to meet specific product shelf-life requirements

Cleanroom production to minimize contamination risk

Export experience in more than 20 countries including Indonesia, Russia, and the EU

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Conclusion

Alu-Alu base foil is not just a packaging material—it’s a protective shield for your product’s quality and your brand’s reputation. For pharmaceutical companies targeting humid or high-temperature markets, this packaging solution ensures product stability and patient safety.

Contact HEALTHPLAST today to discuss your specific Alu-Alu foil requirements and request technical samples.