Pharmaceutical Packaging Pouches for API & Drug Packaging

The integrity of a medicine is fundamentally linked to its packaging. In the highly regulated world of pharmaceuticals, the packaging is not merely a container; it is the first line of defense against environmental antagonists: moisture, oxygen, and ultraviolet (UV) light. These elements are major culprits in drug degradation, leading to reduced efficacy, altered chemical properties, and a shortened pharma packaging shelf life extension. Choosing the right pharmaceutical packaging solutions is a non-negotiable step for any company committed to regulatory compliance and patient safety. 

Moisture, Oxygen, and UV Light Degrading Materials over Time

Active Pharmaceutical Ingredients (APIs) and finished drug products are inherently sensitive. Exposure to environmental stress can trigger chemical reactions, such such as hydrolysis (caused by moisture) and oxidation (caused by oxygen), which degrade the medication. UV light, a high-energy form of radiation, can break down molecular bonds, leading to photolytic degradation. The core mission of modern pharma packaging solutions is to create an impermeable barrier against this triple threat, ensuring the drug maintains its potency from the manufacturing floor to the patient's hand.

When Moisture Takes Over

Water vapor transmission is arguably the most critical factor in packaging solid dosage forms like tablets and capsules, as well as highly hygroscopic API powders. A high Water Vapor Transmission Rate (WVTR) in the packaging material allows moisture to penetrate, causing medicines to clump, dissolve prematurely, or lose their therapeutic effect. Moisture-resistant pharmaceutical packaging is paramount for preventing this.

Oxygen: The Oxidative Enemy

Oxygen ingress can lead to oxidative degradation, particularly in vitamins, biologics, and certain API powders. This process can change the color, odor, or chemical structure of the drug. Effective packaging solutions must demonstrate an extremely low Oxygen Transmission Rate (OTR) to maintain a stable, inert environment around the product.

UV Light: The Photolytic Risk

Many drug compounds are photosensitive. Direct or indirect exposure to UV light can initiate photochemical reactions that compromise the drug's stability. For this reason, UV protection packaging for medicines is essential, often achieved through opaque materials or color additives in glass or plastic.

Leading-Edge Pharmaceutical Packaging Solutions

The industry employs a variety of high-performance pharmaceutical packaging solutions to combat environmental factors. The choice of material often depends on the drug’s sensitivity, dosage form, and required pharma packaging shelf life extension.

1. Aluminum-Based High-Barrier Solutions

Aluminum is universally recognized as the gold standard for barrier properties.

Medicines are no less than miracles, but these miracles only work when their potency is protected. Sometimes, in the pharmaceutical industry, medicines have to travel quite a long way before reaching the patient. The journey is complex, and many stages need to be crossed! In these stages, many obstacles might affect the potency of medicines, such as moisture, oxygen, light, and contamination if the packing solutions are not up to the mark!

That’s why the topmost importance is given to packaging solutions in the entire process.

Medicines come in various forms like tablets, liquid, and powder, so they not only need to be protected from moisture, oxygen, light, and contamination, but they also require customization in terms of size, shape, and quantity. A packaging solution that ticks all the boxes is the one that wins.

Types of Packaging Solutions

A diverse array of packaging formats is available to meet the unique requirements of different products. Common packaging solutions for tablets and capsules include various options, each designed to cater to the specific needs of the medicine.

Given that each medicine comes in a variety of shapes, forms, and components, it's crucial to understand their special requirements and develop the appropriate packaging solution.

Let's delve into the top 3 types of packaging solutions -

1.  Pharma Grade Bags

Pharma-grade bags are among the most crucial laminated materials in the pharmaceutical industry. These specialized bags are designed and manufactured to meet the high standards that pharmaceutical and healthcare applications require.

Medicines often need to be transported from one location to another for various reasons, and this process carries the risk of damage due to varying moisture levels in different environments. These specially designed bags ensure the safe and efficient transfer of medicines.

They are moisture-resistant, odorless, and non-toxic, making them ideal for protecting pharmaceuticals during transportation.

The pharma-grade bags meet the standards and regulations set by the FDA. Apart from being excellent in quality, these bags are also very helpful in extending the shelf life of pharma products. They are produced without any harmful chemicals or additives, assuring no adverse effect on the tablets, capsules, or drugs packed in the bags.

Benefits of Pharma grade bags:

• High-quality material - medical-grade plastic, polypropylene, polyethylene, and other materials are used in the formation of these bags. These materials are resistant to chemicals, moisture, and contaminants.

• Tamper-evident - medicines need to be packed and sent here and there for multiple reasons, such as testing, examining, etc., before they are sent to the market for sale. That simply means double protection is required! These bags have features such as tamper-evident seals or closures that secure the product.

• Regulatory Compliance -The pharma-grade bags meet the high standards and regulations set by the FDA.

• Customizability - Pharma-grade bags can be designed in various shapes, types, and sizes depending on the need of the medicine they are intended to hold.

Common uses of Pharma Grade Bags: Active Pharmaceutical Ingredients (APIs), excipients, pharmaceutical powders, tablets and capsules, cleanroom packaging, etc.

2.  Medical Grade LDPE Bags

The medical grade LDPE bags are made from low-density polyethylene, which means they assure a safe, secure, and compliant packaging of medicines.

These bags are commonly used for the packaging of bulk medicines/pharmaceutical ingredients, bulk raw materials, and APIs. The bulk transportation and storage of such products require a safe and sterile environment; that's why the medical-grade LDPE bags are considered the best option.

Benefits of Medical Grade LDPE Bags—

• Non-toxic - LDPE is a non-toxic material, which makes it the safest option for packaging products, as it would cause no harm to human health despite the time duration.

• Reliable - From manufacturing to packing and distribution, the medicines have a long journey to travel; medical-grade LDPE bags became the most reliable option.

• Inexpensive - LDPE bags are cheaper than other materials, a cost-effective solution for packaging needs.

•  Moisture resistance - LDPE bags act as a shield to moisture, even in extremely humid conditions, which helps in maintaining the potency of pharmaceutical products.

Common use of medical grade bags: pharmaceutical packaging, sterilization, sample collection and storage, cleanroom applications, etc.

3.  Triple Laminated Aluminium Moisture Barrier Bags

Triple-laminated bags are one of the most common and popular packaging solutions for pharmaceutical and drug products. They are made with low-density polyethylene (LDPE) that helps keep the product safe from moisture's damaging effects.

The laminated bag is very useful for those medicines that need to be stored for a longer duration.

In the pharma industry, medicines or such products are packed and transported to various locations. This requires a great deal of packing, or else moisture exposure can reduce the bioavailability of the medicines. In such situations, the triple-layer plastic film bag protects the product, disallowing the odor, moisture, and toxins to enter and harm the potency of the drug.

The Benefits of Triple-Laminated Aluminium Moisture Barrier Bags

• Longer storage - The laminated bags are most commonly used when the product requires being stored safely for a longer duration.

• High temperature resistance - the triple laminated bags are specially designed to withstand high temperatures, making them ideal for storing and transporting products that might be exposed to fluctuating heat.

• Complete climate protection- these bags protect the medicines/products from various environmental factors like temperature change, moisture, and light exposure.

• Lightweight - these bags are light in weight despite their strong and layered capabilities. This quality makes them easy to handle, transport, and store without adding unnecessary weight.

Common use of Triple laminated aluminium moisture barrier bags: Pharmaceuticals and Bulk Drugs, the food industry, chemicals and dyes, machinery packaging, etc.

Conclusion

Pharma-grade bags, medical-grade LDPE Bags, and triple-laminated aluminum moisture Barrier Bags are some of the top packaging solutions that offer exceptional protection, regulatory compliance, and customization.

 By leveraging these high-quality packaging options, the pharmaceutical industry can ensure that medicines reach patients in their most effective form, maintaining their intended therapeutic benefits.

LDPE bags find their usage and applications in various important processes to safeguard pharmaceutical and cleanroom packaging. They are the best moisture, humidity, and contamination solution for packaging of potent, important pharma drugs, diagnostic kits, devices, and many more products in a very efficient way. Low-density polyethylene (LDPE) bags are widely used across various industries due to their flexibility and strength.

What is a Poly Bag?

Poly bags are sturdy, durable, and flexible plastic bags that are mainly made from polyethylene, which has many useful properties and uses in the packaging needs across industries. There are two main types of polyethylene used to create these bags: Low-Density Polyethylene (LDPE) and High-Density Polyethylene (HDPE).

LDPE bags are lightweight, soft, inert, sturdy, and flexible, and that’s why they are ideal for packaging items that require protection from moisture and dust, like food, pharma, and cleanroom products.

HDPE bags are stronger and more rigid when compared to LDPE bags. Though they are not very flexible, they are highly durable, which makes them great for packaging heavy items like construction materials or sharp-edged products, cleanroom packaging, diagnostic kits, pharmaceutical equipment, etc.

Benefits of LDPE Bags

When LDPE bags are used for pharmaceutical and cleanroom packaging, they provide a lot of benefits.

High flexibility bags: LDPE bags are very flexible, which helps them fit the shape of their packaging inside. This flexibility is useful for packing items that are not of regular shape and can provide a tight fit and improved protection from damage during packaging, storage, and transportation.

Provide great moisture resistance: LDPE bags can effectively protect the contents from excess or varying moisture levels outside, in turn keeping the products dry and safe. This is very important during the packaging of food products, pharma products, and cleanroom packaging that can be easily damaged due to excess moisture levels.

Provide high chemical resistance: LDPE bags are inert and non-toxic which means they are resistant to many chemicals, making them suitable for packaging of various substances, especially chemicals and other products. This property is important in industries where products may come into contact with harmful chemicals and can alter or damage the product being stored in the LDPE bags.

Transparent bags for storage: LDPE and HDPE bags are transparent and thus provide a clear view of their packing and contents. This is very beneficial as it is a convenient way to package products and helps in sorting and identifying them.

Sustainable and eco-friendly solution to packaging: LDPE bags can be recycled, which lowers their impact on the environment. Recycling these bags helps cut down on plastic waste and supports a more sustainable way of using packaging in our everyday lives.

LDPE vs HDPE Bags

Let us compare the two types of polyethylene bags available for moisture and contamination free packaging.

Recycling Differences

The recycling processes for LDPE and HDPE bags can differ mainly due to their material and their properties. LDPE bags can be more challenging to recycle because of their softness, which can cause them to clog in recycling machines. The process can involve steps of collecting, sorting, cleaning, and then melting the plastic into new products. 

HDPE bags, are much easier to recycle due to their rigidity and structure, and undergo a similar process of recycling. Recycling HDPE is usually better for the environment because it is more efficient and has higher recycling rates, which helps reduce plastic waste. On the other hand, recycling LDPE has issues such as contamination and lower market value. But, both types of recycling are important and can greatly help by reducing landfill waste and saving resources.

Industries Using Both LDPE and HDPE

There are many industries that use both LDPE and HDPE packaging for their applications and processes.

Medical Devices: LDPE bags are very commonly used in the medical industry to package devices, to make sure they remain sterile and protected from detrimental factors such as moisture, dust, contamination, oxygen, etc. Their flexibility and moisture resistance make them ideal for safely storing sensitive medical equipment.

Packaging: Both LDPE and HDPE bags are used for the safe and efficient storage in the packaging industry of different products. LDPE is often used for heat-sealed packaging, while HDPE is preferred for strong, durable containers that can hold heavier items safely.

Life Sciences: LDPE and HDPE bags help prevent contamination of products in the life sciences sector, due to their non-toxic properties which greatly ensure safety while packaging pharmaceuticals and laboratory materials. This in turn helps in maintaining quality and integrity during storage and transport throughout their shelf life efficiently.

Who Shouldn’t Use LDPE Bags?

A few applications and certain industries should avoid using LDPE bags. For example, the construction industry requires packaging that has high-strength properties to safely transport, and package, heavy construction materials like cement and bricks, and LDPE bags are not strong enough for these applications.

In high-temperature environments such as food processing or certain manufacturing settings and applications, LDPE bags may not be useful or the right choice as they can deform or melt under heat becoming not useful for such packaging needs or requirements.

LDPE Poly Bags: Cleanroom Uses

Following and maintaining high and important cleanroom standards is a high priority because they help maintain a sterile environment, and mainly prevent contamination from dust and microorganisms. This is especially important in industries like pharmaceuticals and medical devices, where even tiny particles can affect product safety. LDPE bags are commonly used in cleanrooms to package sensitive items, ensuring they remain uncontaminated during storage and transport.

There are many advantages of using LDPE bags in cleanroom settings as they provide great control over contamination because they are made to reduce particle release. Their flexible design makes it easy to handle and store different items, which helps keep things clean and protects important products in sensitive environments.

It is best to use premium quality LDPE and HDPE bags from a trusted manufacturer and supplier like Sorbchem India. Our polyethylene bags are made with the highest standard materials and are the best sustainable packaging solution for your needs. 

Pharmaceutical products are highly potent, important, and high-demand products in the market, so proper care should be taken to safeguard them from detrimental factors like moisture, excess oxygen, humidity, dust, etc. LDPE bags are the best moisture and safety packaging solution for packaging and storing pharmaceutical products effectively. These bags are inert and do not react with the contents of the packaging, are non-toxic, provide excellent barrier properties from the external environment, and are designed to withstand various harsh or changing conditions during storage and transportation.

Understanding LDPE Bags

Low-Density Polyethylene (LDPE) is a kind of plastic created from ethylene, that is basically made of hydrocarbon. Its special structure has long, branched chains of molecules, which makes it highly low density in nature, sturdy, flexible, and also resistant to humidity and water.

LDPE is lightweight and durable and that is why it is the perfect material for packaging pharmaceutical products in the form of different packaging uses like bags and films. It can also withstand and resist many chemicals, which helps keep the products safe inside.

Let us check out the process of making LDPE bags in short, which starts by heating LDPE granules until they turn into liquid. This liquid plastic is then formed into bags using molds or by blowing air to create a thin film. And once cooled, the bags are cut and packaged for shipping as per the sizes required.

Benefits of Using LDPE Bags in Pharmaceutical Packaging

There are many benefits of using LDPE bags for the packaging of pharma products, as compared to other methods or materials available.

Safety Features:

Barrier Properties: LDPE bags have good barrier properties which help them perfectly protect and safeguard the contents of the packaging from external elements such as dust, moisture, humidity, heat, contamination, etc., and maintain their quality throughout storage and transportation.

Chemical Stability: LDPE material is resistant to many chemicals, which means it does not react with the medications that are packaged inside. This stability ensures that the integrity of pharmaceutical products is preserved, preventing any unwanted changes in their effectiveness.

Sustainability Aspects:

Recyclability: LDPE bags can be recycled, which helps reduce waste and the need for new plastic production. Recycling LDPE lowers energy consumption and greenhouse gas emissions, making it a more environmentally friendly option for the packaging of pharma products that are consumed regularly and may create more packaging waste once discarded.

Energy Efficiency: The production and disposal process of LDPE packaging bags mostly consumes less energy compared to other packaging materials, and it is this efficiency that contributes to a smaller carbon footprint, making LDPE bags a sustainable choice for pharmaceutical packaging.

Economic Benefits:

Cost-effectiveness: Pharma bags are generally less expensive to produce than many other traditional packaging options. Their lightweight nature also reduces shipping costs, and their recyclability also helps reduce costs, making them an economical choice for large-scale pharmaceutical packaging needs.

Comparison with Other Packaging Materials

Let us see how LDPE packaging bags or films compare to the other available packaging materials for the pharma products.

Advantages of LDPE Bags:

• LDPE safety bags are easy to handle during the packaging, storage and transportation of potent pharmaceutical drugs and products, making them the best option for packaging material in pharma industry.
• Using LDPE bags helps lower the environmental impact compared to heavier materials, as they require less energy to produce and transportation, thus saving more energy consumption.

Here are a few examples of companies that use pharmaceutical packaging solutions in the packaging of pharma products. Pfizer uses LDPE bags for packaging some of their products, benefiting from reduced shipping costs and improved product safety. And Novartis implements LDPE bags in their supply chain, enhancing sustainability efforts while maintaining product integrity.

Applications in the Pharmaceutical Industry

Here are some important and useful applications of sustainable pharmaceutical packaging, bags, pouches, and films in the pharmaceutical industry.

Primary Packaging: LDPE bags are often used for primary packaging, which means they come into direct contact with the packaged pharmaceutical products. They are suitable for packaging items like powders, gels, tablets, nutraceutical products, and capsules which effectively protect the contents from moisture, oxygen, and contaminants, helping to maintain the quality and effectiveness of the medications throughout their shelf life and storage.

Secondary Packaging: These pharma bags are also used in secondary packaging, which means they are used as outer packaging to protect primary containers. This extra layer of protection helps ensure that the medications remain safe during transportation and storage and can also protect against any spills or spoilage.

Compliance and Regulations: Since the pharmaceutical products are potent, important, and sensitive products, they are greatly governed by strict regulations and compliances. Organizations like the USFDA and the ISO have set some regulations and guidelines that these bags must meet to ensure product safety and quality. Eco-friendly packaging bags are designed to be non-toxic and chemically inert, which means they do not react with the medications they hold. It is important to follow these compliances to maintain the quality of pharmaceutical products throughout their shelf life.

Innovative Uses of LDPE in the Pharmaceutical Sector

Many advances in how these bags are made are increasing their strength and effectiveness in protecting medicines. There is also a growing focus and need for sustainability in the industry, and that is why LDPE bags are becoming the most preferred and perfect solution for packaging of pharma products against the detrimental environmental factors.

Companies are also looking into biodegradable and compostable alternatives for LDPE bags to lessen their environmental impact to develop packaging that is safe for products and more eco-friendly. With advancements in technology and a focus on sustainability, LDPE bags will keep changing and remain important in pharmaceutical packaging.

Conclusion

LDPE bags and pouches have the right material, structure, properties, and uses to be applied in the packaging of various different pharmaceutical products effectively. Make sure to buy recyclable packaging materials made with premium materials and are compliant with the necessary regulations and compliance of the pharma industry. Sorbchem India is the largest manufacturer and supplier of high quality, high barrier LDPE bags used in the pharmaceutical industry that enhance safety and sustainability.