Black Box unlocks secrets of pharma blister packs

Amcor said its Black Box software is the first in the industry that allows companies to model a blister pack's finished dimensions and barrier performance, providing quantifiable projections of blister thickness at multiple points within each cavity. It can also make direct comparisons between different blister film materials for their barrier performance, claims the company.

"This service is of increasing importance,"​ said Amcor, alluding to the rising use of high-barrier materials demanded by the growing complexity of pharmaceutical products and rising use of moisture-sensitive formulations such as fast-melt tablets.

Thinning of the blister film during thermoforming can be significant and inconsistent within a single cavity - and vary from cavity to cavity - and this can lead to inconsistencies in barrier performance.

Amcor maintains that Black Box can eliminate a lot of the guesswork that has traditionally been involved in material selection and package design. As a result , pharmaceutical companies can complete packaging studies more quickly and efficiently, according to the firm, which said this should speed up new drug launches and reduce testing costs.

Black Box is also useful for package redesigns, quickly identifying alternative barrier materials, said Amcor.